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Maintenance, Inspection and Thorough Examination of Mobile Cranes

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HSE<br />

Logo<br />

When<br />

Approved<br />

<strong>Maintenance</strong>, <strong>Inspection</strong><br />

<strong>and</strong><br />

<strong>Thorough</strong> <strong>Examination</strong><br />

<strong>of</strong><br />

<strong>Mobile</strong> <strong>Cranes</strong><br />

Suitable picture <strong>of</strong> <strong>Mobile</strong><br />

Crane undergoing<br />

maintenance or thorough<br />

examination<br />

Best Practice Guide<br />

Draft for Public Comment


Reference No. CIG 0901<br />

First Published: XXX 2009<br />

<strong>Maintenance</strong>, <strong>Inspection</strong><br />

<strong>and</strong><br />

<strong>Thorough</strong> <strong>Examination</strong><br />

<strong>of</strong><br />

<strong>Mobile</strong> <strong>Cranes</strong><br />

Published by:<br />

Crane Interest Group (CIG)<br />

Construction Plant-hire Association<br />

27/28 Newbury St<br />

London<br />

EC1A 7HU<br />

Telephone: 020 7796 3366<br />

Email: enquiries@cpa.uk.net<br />

CPA Copyright – XXX 2009<br />

CPA Best Practice Guide<br />

HSE Logo<br />

when approved<br />

Working in Partnership


Contents<br />

Foreword 1<br />

1. Introduction <strong>and</strong> Summary 2<br />

2. Definitions 6<br />

3. Legal Requirements 8<br />

4. Approaches to <strong>Maintenance</strong> 11<br />

5. <strong>Maintenance</strong> Intervals 15<br />

6. <strong>Maintenance</strong> Personnel - Attributes, Training <strong>and</strong> Assessment 17<br />

7. Information for <strong>Maintenance</strong> 20<br />

8. <strong>Inspection</strong> During <strong>Maintenance</strong> 22<br />

9. <strong>Maintenance</strong> Records 24<br />

10. Management Review <strong>of</strong> <strong>Maintenance</strong> Records 26<br />

11. Site Issues for <strong>Maintenance</strong> 27<br />

12. Spare Parts 30<br />

13. <strong>Maintenance</strong> Facilities <strong>and</strong> Equipment 33<br />

14. Approaches to <strong>Thorough</strong> <strong>Examination</strong> 39<br />

15. Management <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong> 44<br />

16. Competent Persons – Attributes, Training <strong>and</strong> Assessment 47<br />

17. Developing the Defined Scope <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong> 51<br />

18. Reports <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong> 55<br />

19. Management Review <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong> Records 57<br />

20. Practical Issues for <strong>Thorough</strong> <strong>Examination</strong> (Best Practice in Depots) 58<br />

21. Practical Issues for <strong>Thorough</strong> <strong>Examination</strong> on Site 61<br />

Page<br />

22. Lifting Accessories 65


Annex 1 Work at Height 66<br />

Annex 2<br />

Annex 3<br />

Annex 4<br />

Example <strong>of</strong> a typical Safe System <strong>of</strong> Work for <strong>Thorough</strong><br />

<strong>Examination</strong> Activities<br />

Example <strong>of</strong> a Defined Scope <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong> for a<br />

<strong>Mobile</strong> Crane<br />

Sample Document Covering <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong><br />

<strong>Examination</strong> Issues for <strong>Mobile</strong> Crane Users<br />

Annex 5 Typical In-service <strong>Maintenance</strong> Schedule 92<br />

Annex 6 Daily Pre-use Checks <strong>and</strong> Weekly <strong>Inspection</strong>s 93<br />

Annex 7 Example <strong>of</strong> a Lift Accessory Register 94<br />

Annex 8<br />

Annex 9<br />

Annex 10<br />

Example <strong>of</strong> the Use <strong>of</strong> Key Performance Indicators for<br />

<strong>Maintenance</strong><br />

Example <strong>of</strong> the Use <strong>of</strong> Key Performance Indicators for<br />

<strong>Thorough</strong> <strong>Examination</strong><br />

Supplementary Reports <strong>and</strong> Tests Supporting <strong>Thorough</strong><br />

<strong>Examination</strong><br />

Annex 11 Qualifications <strong>and</strong> Assessment <strong>of</strong> <strong>Maintenance</strong> Personnel 103<br />

Annex 12 “Grey” Imports 104<br />

Bibliography 106<br />

Index 109<br />

Working Group Membership 110<br />

74<br />

82<br />

88<br />

95<br />

97<br />

98


Foreword<br />

Every year, the construction industry is responsible for causing deaths <strong>and</strong><br />

serious injury. In recent times the industry has done much to improve its<br />

performance which I welcome, but there is always room for<br />

more improvement.<br />

Our construction industry relies on the use <strong>of</strong> mobile cranes to move materials<br />

on sometimes small, confined sites. <strong>Mobile</strong> cranes are an essential part <strong>of</strong> the<br />

construction process <strong>and</strong> can help resolve some <strong>of</strong> the safety problems on<br />

site arising from space constraints.<br />

<strong>Mobile</strong> cranes are <strong>of</strong>ten used in close proximity to people. The transportation,<br />

set up <strong>and</strong> use <strong>of</strong> mobile cranes provide the potential for death <strong>and</strong> serious<br />

injury to occur <strong>and</strong> indeed tragically, both site workers <strong>and</strong> members <strong>of</strong> the<br />

public <strong>of</strong>f site have been killed in mobile crane accidents. In addition to the<br />

terrible cost in human suffering, accidents have a financial cost. There is a<br />

very strong business case for improving safety performance.<br />

The law relating on cranes is clear. There are requirements to ensure that<br />

cranes are inspected, examined <strong>and</strong> maintained to ensure they do not present<br />

a risk. However, investigations into recent accidents have shown that<br />

enhanced st<strong>and</strong>ards <strong>of</strong> maintenance <strong>and</strong> thorough examination could have<br />

reduced the chance <strong>of</strong> death or injury.<br />

This guidance has been prepared to provide clarity about the practical<br />

elements <strong>of</strong> maintenance, inspection <strong>and</strong> thorough examination. The<br />

guidance is simple but comprehensive <strong>and</strong> easy to adopt. It represents best<br />

practice for mobile cranes used in the construction industry <strong>and</strong> is equally<br />

applicable to all mobile crane use across all industry sectors.<br />

I thank those who have been involved in its preparation <strong>and</strong> commend the<br />

guidance to anyone who owns supplies or controls the operation <strong>of</strong> mobile<br />

cranes. Please read the publication <strong>and</strong> turn the advice into action.<br />

Picture<br />

Phillip White<br />

HM Chief Inspector <strong>of</strong> Construction<br />

Chair <strong>of</strong> the Construction Industry Advisory Committee (CONIAC).<br />

1


1.0 Introduction <strong>and</strong> Summary<br />

The consequences <strong>of</strong> any failure <strong>of</strong> a mobile crane are likely to be extremely serious,<br />

with the potential for multiple fatalities. <strong>Mobile</strong> cranes, which include wheeled <strong>and</strong> ,<br />

crawler cranes, compact cranes <strong>and</strong> mobile tower cranes, are also <strong>of</strong>ten one <strong>of</strong> the<br />

primary means <strong>of</strong> material h<strong>and</strong>ling on a construction site <strong>and</strong> any breakdown will<br />

have a serious effect on the construction programme. It is therefore extremely<br />

important that mobile cranes are effectively maintained to ensure continued safe <strong>and</strong><br />

efficient operation over time.<br />

In addition to the maintenance process the thorough examination <strong>of</strong> mobile cranes,<br />

periodically <strong>and</strong> after exceptional circumstances is required to ensure that mobile<br />

cranes are safe to take into use <strong>and</strong> to continue in use.<br />

Both the maintenance <strong>and</strong> thorough examination <strong>of</strong> mobile cranes are required by<br />

law <strong>and</strong> the purpose <strong>of</strong> this Best Practice Guide (BPG) is to set out, in clear <strong>and</strong><br />

concise terms, both the requirements <strong>and</strong> Best Practice for meeting these<br />

requirements. The document is split into two sections – <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong><br />

<strong>Examination</strong>, to emphasise that these are separate, although complimentary,<br />

activities. The document is aimed primarily at mobile crane owners, <strong>and</strong> those<br />

managing <strong>and</strong> carrying out the maintenance <strong>and</strong> thorough examination <strong>of</strong> mobile<br />

cranes. However the document will also be <strong>of</strong> benefit to other groups such as mobile<br />

crane users.<br />

<strong>Maintenance</strong><br />

There are a number <strong>of</strong> equipment maintenance management techniques that can be<br />

employed, including “Breakdown <strong>Maintenance</strong>” where maintenance is only carried<br />

out after faults or failures have occurred, <strong>and</strong> “Planned Preventive <strong>Maintenance</strong>”<br />

which involves routine inspection replacing parts <strong>and</strong> consumables or making<br />

necessary adjustments at preset intervals, so that risks do not occur as a result <strong>of</strong> the<br />

deterioration or failure <strong>of</strong> the equipment.<br />

In the case <strong>of</strong> mobile cranes the “Breakdown” approach is inappropriate, as any<br />

failure presents an immediate risk. The Best Practice Guidance is therefore the<br />

“Planned Preventive <strong>Maintenance</strong>” management technique.<br />

<strong>Maintenance</strong> <strong>of</strong> mobile cranes should be managed in the same way as any other<br />

business activity as, if not carried out effectively, it can have severe financial <strong>and</strong><br />

safety implications for a business. An effective management structure is required to<br />

ensure that everyone involved in the maintenance activity is aware <strong>of</strong> their<br />

responsibilities, properly briefed on their duties <strong>and</strong> that systems are in place to<br />

enable effective feedback, including the monitoring <strong>of</strong> maintenance data.<br />

<strong>Mobile</strong> crane maintenance activities should be carried out, as a minimum, at the<br />

intervals specified in the mobile crane manufacture’s maintenance manual. Varying<br />

circumstances on site may however require the frequency to be increased.<br />

Once a mobile crane has been set up on a site, the user <strong>of</strong> the crane has a duty to<br />

ensure that it is adequately maintained. The actual undertaking <strong>of</strong> the maintenance is<br />

generally delegated to the crane owner by the user; the user however, retains the<br />

responsibility for ensuring that the maintenance is carried out.<br />

Clear lines <strong>of</strong> responsibility for maintenance operations should be established from<br />

Board level downwards, ensuring that those appointed <strong>and</strong> responsible have<br />

sufficient knowledge <strong>and</strong> experience to carry out their duties in a way which will<br />

ensure that risks are properly controlled.<br />

2


Each mobile crane should have a documented preventive maintenance schedule<br />

which is targeted at the parts <strong>of</strong> the equipment where failure or deterioration could<br />

lead to health <strong>and</strong> safety risks <strong>and</strong> which specifies the frequency <strong>of</strong> inspection <strong>and</strong><br />

test <strong>of</strong> relevant parts, taking account <strong>of</strong> the manufacturer’s instructions, the age <strong>of</strong> the<br />

crane <strong>and</strong> its in-use history.<br />

<strong>Mobile</strong> crane owners may not have access to expert pr<strong>of</strong>essional engineering advice<br />

in-house. If this is the case arrangements should be made for securing such advice<br />

externally where this is necessary for the purposes <strong>of</strong> health <strong>and</strong> safety <strong>and</strong> clear<br />

guidelines should be established for when this advice should be sought.<br />

For a preventive maintenance system to be fully effective it is essential that<br />

comprehensive records <strong>of</strong> daily checks, intermediate inspections, breakdown reports,<br />

maintenance work sheets (including details <strong>of</strong> parts replacement) <strong>and</strong> reports <strong>of</strong><br />

thorough examination are kept. These should be filed in an individual machine history<br />

file which should be kept for the life <strong>of</strong> the crane.<br />

An extremely important aspect <strong>of</strong> a planned preventive maintenance system is the<br />

continuous <strong>and</strong> systematic review <strong>of</strong> all maintenance records, inspection reports <strong>and</strong><br />

reports <strong>of</strong> thorough examination to ensure that the maintenance is effective, defects<br />

are found <strong>and</strong> worn components are replaced well in advance <strong>of</strong> any possible failure.<br />

Should this review indicate that maintenance is not fully effective, the frequency may<br />

have to be increased <strong>and</strong> maintenance practices amended.<br />

<strong>Maintenance</strong> should only be carried out by those who are competent <strong>and</strong> have<br />

adequate training <strong>and</strong> information to carry out the work required. A number <strong>of</strong><br />

general maintenance training courses <strong>and</strong> qualifications are available for personnel<br />

carrying out <strong>and</strong> supervising maintenance operations. Training is <strong>of</strong>fered by a<br />

number <strong>of</strong> training providers including the National Construction College, whilst<br />

qualifications are available through the NVQ/SVQ scheme.<br />

All maintenance personnel should have received machine specific training, traceable<br />

to the mobile crane manufacturer, before carrying out maintenance tasks on any<br />

mobile crane.<br />

<strong>Maintenance</strong> operations on mobile cranes require adequate facilities <strong>and</strong> equipment<br />

to enable them to be carried out effectively, efficiently <strong>and</strong> safely. The size <strong>and</strong><br />

sophistication <strong>of</strong> the facilities will depend on the degree <strong>of</strong> maintenance tasks to be<br />

carried out.<br />

<strong>Thorough</strong> <strong>Examination</strong><br />

<strong>Thorough</strong> examination <strong>of</strong> lifting equipment is a fundamental requirement <strong>of</strong> the Lifting<br />

Operations <strong>and</strong> Lifting Equipment Regulations 1998 (LOLER). Regulation 9 <strong>of</strong> the<br />

Lifting Operations <strong>and</strong> Lifting Equipment Regulations 1998 (LOLER) requires<br />

employers to ensure that mobile cranes are thoroughly examined at prescribed<br />

intervals. In the case <strong>of</strong> a hired-in mobile crane the actual undertaking <strong>of</strong> thorough<br />

examinations is <strong>of</strong>ten delegated to the crane owner by the user. The user however,<br />

retains the legal responsibility for ensuring that thorough examinations are carried<br />

out.<br />

The primary purpose <strong>of</strong> a thorough examination is to ensure that a mobile crane is<br />

safe to be taken into, or to continue in, use. It is in addition to any inspection carried<br />

out as a part <strong>of</strong> the maintenance regime <strong>and</strong> is a statutory requirement.<br />

<strong>Mobile</strong> cranes operate in a high risk environment which includes lifting loads over<br />

people. These factors must be taken into account by the competent person when<br />

determining the scope <strong>and</strong> nature <strong>of</strong> the thorough examination.<br />

As with maintenance, the thorough examination <strong>of</strong> mobile cranes should be managed<br />

effectively, irrespective <strong>of</strong> whether thorough examination is carried out in-house or by<br />

3


a third party. An effective management structure is required to ensure that everyone<br />

involved in the thorough examination activity is aware <strong>of</strong> their responsibilities,<br />

properly briefed on their duties <strong>and</strong> that systems are in place to enable effective<br />

feedback, including the monitoring <strong>of</strong> thorough examination outcomes. If thorough<br />

examination is carried out by the organisation owning or supplying the mobile crane,<br />

steps must be taken to ensure that the competent persons carrying out the thorough<br />

examinations have, as LOLER requires “the genuine authority <strong>and</strong> independence to<br />

ensure that examinations are properly carried out <strong>and</strong> that the necessary<br />

recommendations arising from them are made without fear or favour.” This guidance<br />

describes a number <strong>of</strong> ways in which this requirement may be met.<br />

<strong>Thorough</strong> <strong>Examination</strong> <strong>of</strong> mobile cranes should only be carried out by those who are<br />

assessed as competent <strong>and</strong> have adequate training <strong>and</strong> information to carry out the<br />

task. Competent persons should be selected through a formally documented<br />

assessment process <strong>and</strong> any shortfalls in their knowledge or ability addressed<br />

through formal or on the job training. All assessment <strong>and</strong> training must be recorded in<br />

an individual training record, together with the ongoing Continuing Pr<strong>of</strong>essional<br />

Development that should be undertaken by all Competent Persons.<br />

Competent Persons carrying out <strong>Thorough</strong> <strong>Examination</strong>s <strong>of</strong> mobile cranes should be<br />

provided with adequate information to enable them to carry out their duties effectively<br />

<strong>and</strong> safely. The Competent Person may specify supplementary tests to be carried out<br />

prior to or during the <strong>Thorough</strong> <strong>Examination</strong>. These may include such tests as:-<br />

� Overload test following major repair;<br />

� RCI/RCL calibration <strong>and</strong> functional test;<br />

� Hoist brake test;<br />

� Pre-delivery inspections;<br />

� Non Destructive <strong>Examination</strong> <strong>of</strong> individual components.<br />

The results <strong>of</strong> the thorough examination must be reported in writing as required by<br />

LOLER. This includes the reporting <strong>of</strong> safety critical defects to the Enforcing Authority<br />

(Normally the Health <strong>and</strong> Safety Executive).<br />

Four Year Testing <strong>of</strong> <strong>Mobile</strong> <strong>Cranes</strong><br />

<strong>Mobile</strong> cranes in the UK are <strong>of</strong>ten subjected to overload testing at four yearly<br />

intervals. This is a legacy from the requirements <strong>of</strong> the old Construction (Lifting<br />

Operations) Regulations, which were replaced by the introduction <strong>of</strong> LOLER in 1998.<br />

The Approved Code <strong>of</strong> Practice to LOLER states that any testing is at the discretion<br />

<strong>of</strong> the competent person carrying out a thorough examination <strong>and</strong> that the competent<br />

person will decide on the nature <strong>of</strong> the test <strong>and</strong> the method <strong>of</strong> carrying it out.<br />

In drafting this guidance the CPA, HSE, SAFed <strong>and</strong> the other organisations involved<br />

have concluded that four yearly overload testing is not required where periodic<br />

thorough examinations are carried out to a defined scope, unless deemed necessary<br />

by the competent person. (See 14.0)<br />

Availability <strong>of</strong> <strong>Mobile</strong> <strong>Cranes</strong> for <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

<strong>Mobile</strong> cranes, when on a construction site, are <strong>of</strong>ten pivotal to the construction<br />

process <strong>and</strong> Site Managers may be reluctant to release a mobile crane to the owner<br />

to allow maintenance or thorough examination to take place. It is essential that<br />

adequate downtime is built into the construction programme to allow effective<br />

maintenance <strong>and</strong> thorough examinations to be carried out <strong>and</strong> to ensure that<br />

personnel do not feel under pressure to skimp the work. The activities should always<br />

be carried out during the hours <strong>of</strong> daylight <strong>and</strong> the crane operator should be in<br />

attendance to operate the mobile crane as required.<br />

4


Other Issues<br />

In addition to the issues summarised above the guidance also addresses - site<br />

issues, management review <strong>of</strong> records, spare parts, work at height, safe systems <strong>of</strong><br />

work <strong>and</strong> checklists for checks <strong>and</strong> inspections.<br />

This Guidance may be used by Principal Contractors when undertaking vendor<br />

assessment as required by the CDM Regulations.<br />

5


2.0 Definitions<br />

mobile crane<br />

a jib crane mounted on a wheeled or crawler chassis, which is capable <strong>of</strong> travelling<br />

without the need for fixed runways <strong>and</strong> which relies on gravity for stability<br />

maintenance<br />

the process <strong>of</strong> ensuring that a mobile crane is kept in a safe state, in efficient working<br />

order <strong>and</strong> in good repair<br />

thorough examination<br />

examination by a competent person in such depth <strong>and</strong> detail as the competent<br />

person considers necessary to enable them to determine whether the equipment<br />

being examined is safe to be taken into or continue in use<br />

NOTE: The thorough examination is not part <strong>of</strong> the maintenance regime for the equipment but<br />

provides owners with information which could be used to determine the effectiveness <strong>of</strong> the<br />

regime.<br />

competent person<br />

person who has such practical <strong>and</strong> theoretical knowledge <strong>and</strong> experience <strong>of</strong> the<br />

lifting equipment to be thoroughly examined which enables them to detect defects or<br />

weaknesses <strong>and</strong> to assess their importance in relation to the safety <strong>and</strong> continued<br />

use <strong>of</strong> the lifting equipment<br />

competent engineer<br />

person who has such theoretical knowledge <strong>of</strong> the design <strong>of</strong> the lifting equipment as<br />

enables them to assess the design <strong>of</strong> the item in order to establish appropriate<br />

criteria for a thorough examination<br />

competent trainer<br />

person who has such practical <strong>and</strong> theoretical knowledge <strong>and</strong> experience <strong>of</strong> the <strong>of</strong><br />

the training process, together with model specific training received directly from the<br />

crane manufacturer which enables them to provide effective technical product<br />

training<br />

functional testing<br />

operation <strong>of</strong> each motion <strong>of</strong> the appliance without a load applied in order to<br />

determine whether the equipment performs as the manufacturer intended<br />

performance testing<br />

operation <strong>of</strong> each motion <strong>of</strong> the appliance with the rated load applied in order to<br />

determine whether the equipment performs to the manufacturer’s specification<br />

overload testing (static)<br />

operation <strong>of</strong> the appliance with a load exceeding the rated load applied but without<br />

operating the full range <strong>of</strong> motions <strong>of</strong> the appliance in order to determine whether the<br />

appliance is stable, structurally sound <strong>and</strong> fit for the use for which it was designed<br />

6


overload testing (dynamic)<br />

operation <strong>of</strong> each motion <strong>of</strong> the appliance with a load that exceeds the rated load<br />

applied in order to determine whether the appliance is stable, structurally sound <strong>and</strong><br />

fit for the use for which it was designed<br />

non-destructive testing (NDT)<br />

testing carried out on the structure <strong>of</strong> the appliance to establish the presence,<br />

location <strong>and</strong> extent <strong>of</strong> any defects that can affect the integrity <strong>of</strong> that structure<br />

NOTE: The techniques employed for non-destructive testing are such that they do not<br />

damage or alter the material under test. NDT is also known as non-destructive examination<br />

(NDE).<br />

in-service<br />

condition where the crane is h<strong>and</strong>ling loads up to <strong>and</strong> including the rated capacities<br />

within permissible wind speeds <strong>and</strong> other conditions as specified by the manufacturer<br />

during normal operation following thorough examination<br />

out-<strong>of</strong> service<br />

condition where the crane is either not required for use or is out <strong>of</strong> use, without a load<br />

on the load lifting attachment <strong>and</strong> in conditions as specified by the manufacturer<br />

NOTE: These conditions may include a higher wind speed than that permitted for the inservice<br />

conditions.<br />

supplementary tests<br />

appropriate tests <strong>and</strong>/or examinations called for by the competent person where<br />

concerns regarding the condition <strong>of</strong> equipment arise from the thorough examination<br />

or where additional or more arduous use may be taking place<br />

7


3.0 Legal Requirements<br />

3.1 Introduction<br />

The law places duties on persons concerned with mobile cranes, including those who<br />

supply, set up <strong>and</strong> maintain mobile cranes for use, those who undertake thorough<br />

examinations <strong>and</strong> those involved with the use <strong>of</strong> mobile cranes for lifting operations.<br />

This Section outlines those legal duties <strong>and</strong> points the reader towards further<br />

relevant guidance material.<br />

3.2 The Law Outlined<br />

Legislation relating to the use <strong>of</strong> mobile cranes at work includes the:<br />

� Health & Safety at Work etc Act 1974<br />

� Management <strong>of</strong> Health & Safety at Work Regulations 1999/SI3242<br />

� Workplace (Health, Safety & Welfare) Regulations 1992/SI3004<br />

� Provision & Use <strong>of</strong> Work Equipment Regulations 1998/SI2306<br />

� Lifting Operations & Lifting Equipment Regulations 1998/SI2307<br />

� Personal Protective Equipment at Work Regulations 1992/SI2966<br />

� Work at Height Regulations 2005/SI735<br />

� Supply <strong>of</strong> Machinery (Safety) Regulations 2008/SI1597<br />

� The Construction (Design <strong>and</strong> Management) Regulations 2007/SI320<br />

3.3 Health & Safety at Work etc Act 1974 (HSWA)<br />

HSWA places a duty on employers to ensure the health <strong>and</strong> safety <strong>of</strong> employees <strong>and</strong><br />

others who may be affected by their work activities. Similar duties are placed on the<br />

self-employed <strong>and</strong> persons in control <strong>of</strong> premises. Employees, managers <strong>and</strong><br />

directors also have responsibilities. The HSWA also places a duty on mobile crane<br />

owners <strong>and</strong> users, where their work activity involves mobile cranes being used where<br />

they could affect the general public.<br />

3.4 Management <strong>of</strong> Health & Safety at Work Regulations 1999 (MHSWR)<br />

Under MHSWR, employers <strong>and</strong> self-employed people are required to assess risks to<br />

health <strong>and</strong> safety from their undertaking. This includes risks from the use, repair <strong>and</strong><br />

examination <strong>of</strong> mobile cranes on their premises, including the operation <strong>of</strong> the mobile<br />

crane. The risk assessment should identify what measures are needed to comply<br />

with health <strong>and</strong> safety requirements <strong>and</strong> control risk. The duty holder should then put<br />

in place the organisation <strong>and</strong> arrangements to ensure that those measures are<br />

properly implemented.<br />

3.5 The Workplace (Health, Safety & Welfare) Regulations 1992 (WPR)<br />

WPR places duties on employers to ensure, as far as is reasonably practicable, that<br />

their work places are safe <strong>and</strong> without risks to health. The WPR cover matters such<br />

as ventilation, temperature, lighting, electromagnetic radiation <strong>and</strong> cleanliness <strong>of</strong> the<br />

workplace as well as certain basic welfare provisions.<br />

8


2.1<br />

3.6 The Provision & Use <strong>of</strong> Work Equipment Regulations 1998 (PUWER)<br />

PUWER is concerned with such matters as safeguarding <strong>of</strong> dangerous parts <strong>of</strong><br />

machinery, provision <strong>of</strong> appropriate controls, <strong>and</strong> maintenance <strong>of</strong> work equipment<br />

including mobile cranes.<br />

PUWER places duties on any person who has control to any extent <strong>of</strong>:<br />

� work equipment;<br />

� a person at work who uses, supervises or manages the use <strong>of</strong> work<br />

equipment; or<br />

� the way in which work equipment is used at work (including maintenance).<br />

PUWER applies to employers in respect <strong>of</strong> work equipment provided for, or used by,<br />

their employees, self-employed persons in respect <strong>of</strong> work equipment they use <strong>and</strong><br />

other persons, e.g. visitors.<br />

3.7 The Lifting Operations & Lifting Equipment Regulations 1998 (LOLER)<br />

LOLER deals with the specific risks arising from the use <strong>of</strong> work equipment (including<br />

lifting accessories) to lift loads. It builds upon PUWER <strong>and</strong> applies to the same<br />

groups <strong>of</strong> people. LOLER also introduces particular requirements for lifting<br />

equipment which is used to lift people, <strong>and</strong> a requirement for the thorough<br />

examination <strong>and</strong> reporting <strong>of</strong> thorough examination <strong>of</strong> mobile cranes.<br />

3.8 Personal Protective Equipment at Work Regulations 1992 (PPE)<br />

These Regulations impose health <strong>and</strong> safety requirements for the provision <strong>of</strong>, <strong>and</strong><br />

use by, persons at work <strong>of</strong> personal protective equipment. The Regulations require<br />

employers to ensure suitable personal protective equipment is provided without<br />

charge, for their employees <strong>and</strong> also require self-employed persons to ensure<br />

suitable personal protective equipment is provided for them. Requirements are also<br />

imposed on employees <strong>and</strong> self-employed persons for the use, storage <strong>and</strong><br />

maintenance <strong>of</strong> personal protective equipment. Employees are also required to<br />

report to their employer the loss <strong>of</strong> or any obvious defect in personal protective<br />

equipment.<br />

3.9 Work at Height Regulations 2005 (WAH)<br />

The Work at Height Regulations impose health <strong>and</strong> safety requirements for work at<br />

height. These include:-<br />

� organisation <strong>and</strong> planning;<br />

� hierarchy <strong>of</strong> control;<br />

� competence <strong>and</strong> supervision;<br />

� steps to be taken to avoid risk from work at height;<br />

� selection <strong>of</strong> work equipment;<br />

� inspection <strong>of</strong> work equipment.<br />

The Regulations define work at height as:-<br />

(a) work in any place, including a place at or below ground level;<br />

(b) obtaining access to or egress from such place while at work, except by a<br />

staircase in a permanent workplace.<br />

9


3.10 Supply <strong>of</strong> Machinery (Safety) Regulations 2008 (SMSR)<br />

The Supply <strong>of</strong> Machinery (Safety) Regulations are the UK’s implementation <strong>of</strong><br />

European Union Directive 98/37/EC, the “Machinery Directive” which requires that all<br />

machinery (including lifting accessories) supplied into the European Union, meets the<br />

Essential Health <strong>and</strong> Safety Requirements detailed in Schedule 2 Part 1 <strong>of</strong> the<br />

Regulations. Each machine must be accompanied at time <strong>of</strong> supply by an “EC<br />

Declaration <strong>of</strong> Conformity” declaring that the machinery fulfils all the relevant<br />

provisions <strong>of</strong> the Regulations.<br />

3.11 The Construction (Design <strong>and</strong> Management) Regulations 2007 (CDM)<br />

The Construction (Design <strong>and</strong> Management) Regulations place duties on duty<br />

holders including clients, designers <strong>and</strong> contractors in respect <strong>of</strong> the planning,<br />

management <strong>and</strong> monitoring <strong>of</strong> health, safety <strong>and</strong> welfare in construction projects<br />

<strong>and</strong> <strong>of</strong> the co-ordination <strong>of</strong> the performance <strong>of</strong> these duties by duty holders. These<br />

include a duty on every person working under the control <strong>of</strong> another to report<br />

anything that he is aware is likely to endanger health or safety. The Regulations<br />

impose additional duties on clients, designers <strong>and</strong> contractors where the project is<br />

notifiable, defined as likely to involve more than 30 days or 500 person days <strong>of</strong><br />

construction work. These include the duty <strong>of</strong> the client to appoint a CDM coordinator<br />

<strong>and</strong> a principal contractor.<br />

3.12 British, European <strong>and</strong> ISO St<strong>and</strong>ards<br />

St<strong>and</strong>ards do not generally have the force <strong>of</strong> law: the application <strong>of</strong> a st<strong>and</strong>ard is<br />

almost always voluntary, although st<strong>and</strong>ards are very <strong>of</strong>ten used in support <strong>of</strong><br />

legislation, <strong>and</strong> compliance with a st<strong>and</strong>ard is sometimes quoted in legislation as<br />

<strong>of</strong>fering a route to discharging legal obligations. Good examples <strong>of</strong> this are the<br />

references to the BS 7121 series in the Guidance to LOLER.<br />

British st<strong>and</strong>ards are generally restricted to Codes <strong>of</strong> Practice for safe use <strong>of</strong><br />

equipment e.g. BS7121-3:2000 Safe use <strong>of</strong> mobile cranes, whilst European (EN)<br />

st<strong>and</strong>ards cover requirements for basic principles (Type A), common product<br />

requirements (Type B) <strong>and</strong> specific product requirements (Type C) e.g.<br />

EN13000:2004 <strong>Mobile</strong> cranes.<br />

International St<strong>and</strong>ards (ISO) cover both the safe use <strong>and</strong> specification <strong>of</strong> mobile<br />

cranes <strong>and</strong> components. They do not have any legal status but are <strong>of</strong>ten taken as<br />

good practice <strong>and</strong> are cited as normative references in some EN product st<strong>and</strong>ards.<br />

10


4.0 Approaches to <strong>Maintenance</strong><br />

4.1 <strong>Maintenance</strong> System Elements<br />

The introduction to this Best Practice Guide has emphasised the need to ensure that<br />

equipment is maintained, as required by PUWER, so that its performance does not<br />

deteriorate to the extent that it puts people at risk. Many people have a part to play in this<br />

from the mobile crane operator carrying out daily <strong>and</strong> weekly checks, through the user<br />

reporting defects to the crane owner, to the maintenance personnel. Adequate<br />

maintenance can only be achieved by establishing an effective maintenance<br />

management system which should include<br />

� A statement <strong>of</strong> maintenance policy (e.g. Planned Preventive <strong>Maintenance</strong>,<br />

backed up by breakdown repairs <strong>and</strong> supplemented by Predictive <strong>Maintenance</strong> or<br />

in combination);<br />

� Definition <strong>of</strong> roles <strong>and</strong> responsibilities <strong>of</strong> persons involved in the maintenance<br />

activities;<br />

� Systems for the assessment <strong>of</strong> individual competencies;<br />

� A maintenance plan/schedule;<br />

� Written maintenance procedures;<br />

� <strong>Maintenance</strong> records;<br />

� A review <strong>and</strong> audit plan to ensure that the maintenance is suitable <strong>and</strong> sufficient.<br />

4.2 Types <strong>of</strong> <strong>Maintenance</strong> Management<br />

There are three main types <strong>of</strong> maintenance management that may be applied to the<br />

maintenance <strong>of</strong> machines, including mobile cranes: breakdown maintenance, preventive<br />

maintenance <strong>and</strong> predictive maintenance. Not all <strong>of</strong> these are appropriate for the<br />

effective maintenance <strong>of</strong> mobile cranes, as explained below.<br />

4.3 Breakdown <strong>Maintenance</strong><br />

Breakdown or “run-to-failure” maintenance management has a simple <strong>and</strong><br />

straightforward logic. “If it ain’t broke, don’t fix it” is <strong>of</strong>ten seen as a way <strong>of</strong> limiting<br />

expenditure on maintenance <strong>and</strong> keeping costs low. The problem with this approach for<br />

mobile cranes is that any failure could present an immediate <strong>and</strong> unacceptable risk.<br />

Additionally repair costs may well be very high when the machine does break down, <strong>of</strong>ten<br />

at the most inconvenient moment, with considerable downtime whilst repairs are carried<br />

out.<br />

4.4 Planned Preventive <strong>Maintenance</strong><br />

All planned preventive maintenance systems are time driven. In other words,<br />

maintenance tasks are carried out at intervals that are based on actual hours <strong>of</strong> operation<br />

or on an interval <strong>of</strong> time that equates to an average number <strong>of</strong> operating hours or number<br />

<strong>of</strong> operational cycles. The maintenance interval is based on experience <strong>of</strong> breakdowns or<br />

the mean-time to failure (MTTF) as illustrated in Figure 1. The MTTF or bathtub curve<br />

indicates that a newly purchased machine has a higher probability <strong>of</strong> breakdown due to<br />

teething problems in the first few weeks <strong>of</strong> operation. Following this initial period, the<br />

probability <strong>of</strong> failure is relatively low for an extended period until wear <strong>and</strong> deterioration<br />

means that the probability <strong>of</strong> breakdown/failure increases sharply with elapsed time.<br />

11


Figure 1. - The Bathtub Curve<br />

The problem with this approach is that machines wear at different rates over time<br />

depending on variety <strong>of</strong> factors such as environment, frequency <strong>of</strong> use <strong>and</strong> load<br />

spectrum. If maintenance intervals are too great the machine may breakdown<br />

anyway <strong>and</strong> if they are too short maintenance costs may be unnecessarily high.<br />

Inappropriate or poor maintenance can also cause breakdowns.<br />

4.5 Predictive <strong>Maintenance</strong><br />

Predictive maintenance is a condition driven preventive maintenance approach which<br />

instead <strong>of</strong> relying on industry average life statistics (i.e. mean time to failure) to<br />

determine maintenance intervals, uses direct monitoring <strong>of</strong> the machine. This may<br />

include mechanical <strong>and</strong> electrical condition, environmental factors <strong>and</strong> other<br />

indicators such as frequency <strong>of</strong> use <strong>and</strong> load spectrum. These are used to determine<br />

the actual mean time to failure for the individual machine <strong>and</strong> achieve the best<br />

balance between low maintenance costs <strong>and</strong> unplanned failures.<br />

4.6 Best Practice <strong>Maintenance</strong> Regime For <strong>Mobile</strong> <strong>Cranes</strong><br />

In the case <strong>of</strong> mobile cranes, reliance on the “Breakdown” approach is totally<br />

inadequate, as any failure presents an immediate safety risk, whilst at the current<br />

stage <strong>of</strong> mobile crane technology a total “Predictive <strong>Maintenance</strong>” system would be<br />

difficult to implement. Current best practice is therefore “Planned Preventive<br />

<strong>Maintenance</strong>” backed up by repairs following breakdown. This involves replacing<br />

parts <strong>and</strong> consumables or making necessary adjustments, at preset intervals so that<br />

risks do not occur as a result <strong>of</strong> the deterioration or failure <strong>of</strong> the equipment. Some<br />

elements <strong>of</strong> Predictive <strong>Maintenance</strong> such as oil sampling <strong>and</strong> use <strong>of</strong> data logging<br />

records may well be able to be incorporated into the maintenance regime.<br />

4.7 Investigation <strong>of</strong> Excessive Wear or Failure<br />

Where maintenance activities identify excessive, unexpected or unusual wear, or<br />

failure <strong>of</strong> mobile crane components, this must be fully investigated <strong>and</strong> a solution<br />

sought. This may well require engineering assessment, involve the manufacturer <strong>and</strong><br />

must be fully documented. The documentation must be made available to the<br />

12


competent person at the time <strong>of</strong> the next thorough examination as part <strong>of</strong> the<br />

machine history file.<br />

4.8 Management Structure<br />

<strong>Maintenance</strong> <strong>of</strong> mobile cranes should be managed in the same way as any other<br />

business activity as if not carried out effectively it can have severe financial <strong>and</strong><br />

safety implications for a business. An effective management structure is required to<br />

ensure that everyone involved in the maintenance activity is aware <strong>of</strong> their<br />

responsibilities, properly briefed on their duties <strong>and</strong> that systems are in place to<br />

enable effective feedback, including the monitoring <strong>of</strong> maintenance data. A sample<br />

structure is shown in Figure 2 below.<br />

Health, Safety<br />

<strong>and</strong> Environment<br />

Function<br />

<strong>Maintenance</strong><br />

Supervisor<br />

Managing Director<br />

Senior Manager<br />

<strong>Maintenance</strong><br />

Manager<br />

Admin <strong>and</strong><br />

Records<br />

Figure 2. – Typical <strong>Maintenance</strong> Organisation<br />

4.9 Auditing <strong>of</strong> <strong>Maintenance</strong> Systems<br />

Once a maintenance system has been established it is important that it is regularly<br />

audited to ensure that the system is being adhered to <strong>and</strong> that it is functioning<br />

13<br />

Quality <strong>and</strong> Audit<br />

Function<br />

Technical<br />

Purchasing<br />

Fitters Electricians<br />

Stores


correctly. Auditing should be carried out by an auditor from outside the maintenance<br />

organisation with a sufficient degree <strong>of</strong> independence.<br />

If a business has a formal quality management system such as an ISO 9001<br />

accredited system the maintenance activity should be integrated into that system <strong>and</strong><br />

the scheduled audits.<br />

4.10 <strong>Mobile</strong> Crane Users Responsibilities for <strong>Maintenance</strong><br />

The Health <strong>and</strong> Safety at Work etc. Act 1974 sets out a general duty requiring that<br />

work equipment is maintained so that it is safe. This requirement is reinforced by<br />

Regulation 5 <strong>of</strong> the Provision <strong>and</strong> Use <strong>of</strong> Work Equipment Regulations (PUWER)<br />

1998 which requires that “Every employer shall ensure that work equipment is<br />

maintained in an efficient state, in efficient working order <strong>and</strong> in good repair.” In the<br />

case <strong>of</strong> a hired-in mobile crane the actual undertaking <strong>of</strong> the maintenance is <strong>of</strong>ten<br />

delegated to the crane owner by the user. The user however, retains the legal<br />

responsibility for ensuring that the maintenance, including the rectification <strong>of</strong> defects,<br />

is carried out. This point is <strong>of</strong> particular importance where cranes are on long term<br />

hire on a site, as is <strong>of</strong>ten the case with crawler cranes, mobile tower cranes <strong>and</strong><br />

compact cranes.<br />

14


5.0 <strong>Maintenance</strong> Intervals<br />

5.1 Introduction<br />

It is essential that planned preventive maintenance is carried out at intervals which<br />

ensure that worn <strong>and</strong> damaged components are replaced before the mobile crane<br />

becomes unsafe, breaks down or fails. Breakdown will cause downtime <strong>and</strong> a<br />

consequent loss <strong>of</strong> production for the user, whilst a component failure may well result<br />

in a partial or total collapse <strong>of</strong> the crane with potentially fatal consequences for<br />

persons in the vicinity <strong>of</strong> the crane.<br />

5.2 Pre-delivery <strong>Maintenance</strong> <strong>and</strong> <strong>Inspection</strong> Prior to Long Term Hires<br />

Before a mobile crane including crawler or compact cranes is delivered to site for a<br />

long term hire, it should be inspected by maintenance personnel to identify any worn<br />

or faulty components <strong>and</strong> that these are replaced. The results <strong>of</strong> the inspection must<br />

be recorded. This record may be required by the competent person carrying out the<br />

thorough examination <strong>of</strong> the crane.<br />

It is considerably easier <strong>and</strong> less costly to replace components <strong>and</strong> carry out<br />

lubrication <strong>and</strong> adjustments in a depot, than when the crane has been set up on site.<br />

Work on a crane on site may involve work at height <strong>and</strong> presents difficulty in h<strong>and</strong>ling<br />

heavy components.<br />

5.3 In-service <strong>Maintenance</strong> Interval<br />

A mobile crane should be maintained at regular intervals to avoid breakdown, failure<br />

or collapse. The frequency at which maintenance is carried out should be based on<br />

the recommendations contained in the manufacture’s manual for the crane. This<br />

should however generally be taken as the maximum interval as various factors,<br />

including the following may require the maintenance interval to be reduced:-<br />

� Usage – Double shifting, frequent lifting at or near the Rated Capacity, high<br />

cycling, long hoist ropes <strong>and</strong> excessive slewing may accelerate wear <strong>of</strong> all<br />

components;<br />

� Road Use – Excessive travel on the highway;<br />

� Environment – Corrosive environments such as marine or industrial sites<br />

may accelerate corrosion <strong>of</strong> electrical connectors <strong>and</strong> components, drive<br />

train, structural components, fasteners <strong>and</strong> wire ropes;<br />

� Feedback – Feedback from maintenance records, condition monitoring <strong>and</strong><br />

<strong>Thorough</strong> <strong>Examination</strong> reports may indicate accelerated rates <strong>of</strong> wear <strong>and</strong><br />

deterioration.<br />

Once established the current maintenance interval should be recorded in the<br />

machine history file. Any variation from the manufacturer’s recommended intervals<br />

must be recorded <strong>and</strong> justified each time a change is made.<br />

NOTE: The manufacturer’s recommended service interval may be extended in certain<br />

circumstances where predictive maintenance techniques are used.<br />

5.4 Second-h<strong>and</strong> <strong>Mobile</strong> <strong>Cranes</strong><br />

When purchasing second-h<strong>and</strong> mobile cranes their condition should be thoroughly<br />

assessed as nothing can be taken for granted. Second-h<strong>and</strong> cranes may contain<br />

latent defects which may only become apparent when the machine is put into<br />

service. They may have suffered significant damage <strong>and</strong> have been inadequately<br />

repaired. Second-h<strong>and</strong> cranes may also have been imported into the European<br />

15


Community without being modified to meet EU requirements, so called “Grey<br />

Imports”.<br />

The assessment <strong>of</strong> a second-h<strong>and</strong> crane should include a review <strong>of</strong> maintenance<br />

records <strong>and</strong> previous reports <strong>of</strong> thorough examination, together with consultation <strong>of</strong><br />

the manufacturer who may be able to provide details <strong>of</strong> any major repairs etc..<br />

Once the crane’s condition has been fully assessed any necessary repairs can be<br />

carried out <strong>and</strong> an appropriate in-service maintenance interval established (See 5.3).<br />

16


6.0 <strong>Maintenance</strong> Personnel - Attributes, Training <strong>and</strong> Assessment<br />

6.1 Introduction<br />

It is essential that the maintenance <strong>of</strong> mobile cranes is always carried out by<br />

personnel who have been assessed by their employer as competent <strong>and</strong> have<br />

adequate training <strong>and</strong> information to carry out the work required.<br />

6.2 Attributes<br />

<strong>Maintenance</strong> personnel should be:<br />

� Physically fit;<br />

� Comfortable working at height;<br />

� Have a responsible attitude;<br />

� Able to communicate clearly with other personnel on site;<br />

� Aware <strong>of</strong> their own limitations in knowledge <strong>and</strong> experience;<br />

� Fully conversant with the machinery they are required to maintain <strong>and</strong> its<br />

hazards, including operation necessary for maintenance activities;<br />

� Properly instructed <strong>and</strong> trained. Where special machinery is involved this<br />

should include attending appropriate courses given by the<br />

manufacturer/supplier <strong>of</strong> the equipment;<br />

� Familiar with the procedures <strong>and</strong> precautions required for safe work at<br />

height;<br />

� Fully conversant with the appropriate sections <strong>of</strong> the manufacturer’s<br />

instruction manual;<br />

� Familiar with the use <strong>of</strong> permit to work systems where they are required by<br />

the safe system <strong>of</strong> work, <strong>and</strong> able to operate them correctly;<br />

� Familiar with site specific safety requirements (e.g. construction, process<br />

plant, nuclear, docks, airports, railways);<br />

� Aware <strong>of</strong> their responsibilities under the Health <strong>and</strong> Safety at Work Act <strong>and</strong><br />

supporting regulations;<br />

� Trained <strong>and</strong> competent in the pre use inspection, correct wearing <strong>and</strong><br />

limitations <strong>of</strong> their personal protective equipment.<br />

6.3 Training<br />

All mobile crane maintenance personnel should be trained in a set <strong>of</strong> basic skills to<br />

enable them to work safely <strong>and</strong> participate effectively in the maintenance process.<br />

They should not be required to undertake tasks for which they have not been trained<br />

or assessed as competent to carry out. These basic skills should include the<br />

following.<br />

� Underst<strong>and</strong>ing basic health <strong>and</strong> safety requirements, including the risk<br />

assessment process, together with need for site specific safety;<br />

� Slinging <strong>and</strong> signalling;<br />

� Tool skills, including the selection <strong>and</strong> use <strong>of</strong> tools;<br />

� Identification, selection <strong>and</strong> fitting <strong>of</strong> fasteners (including threaded<br />

fasteners);<br />

17


� Use, inspection <strong>and</strong> maintenance <strong>of</strong> fall protection equipment (working at<br />

height);<br />

� Interpretation <strong>of</strong> technical information, use <strong>of</strong> manuals;<br />

� Basic assessment <strong>of</strong> weather <strong>and</strong> ground conditions;<br />

� Product familiarity on all makes <strong>and</strong> models <strong>of</strong> crane on which maintenance<br />

is being carried out;<br />

� Preparing equipment for use including isolation <strong>of</strong> power sources etc;<br />

� Effective communication (including the use <strong>of</strong> radio equipment);<br />

� Carrying out basic adjustments;<br />

� Identifying <strong>and</strong> rectifying basic faults in equipment;<br />

� Assisting with examinations <strong>and</strong> testing.<br />

These basic skills may be augmented by the following as required:-<br />

� Wire rope inspection <strong>and</strong> termination;<br />

� Use <strong>of</strong> specialist tools <strong>and</strong> equipment appropriate to the work being carried<br />

out (including torque wrenches, multipliers <strong>and</strong> hydraulic tensioning<br />

equipment);<br />

� Checking <strong>and</strong> setting limits, including RCI/RCL;<br />

� Downloading data from data acquisition systems;<br />

� Functional testing;<br />

� Carrying out complex adjustments;<br />

� Identifying <strong>and</strong> rectifying complex faults in equipment;<br />

� Identifying proximity hazards;<br />

� Welding <strong>and</strong> repair techniques.<br />

NOTE: Specialist activities such as structural repairs <strong>and</strong> identifying <strong>and</strong> rectifying complex<br />

faults are generally best carried out by the crane manufacturer, who should always be<br />

consulted before any such activities are contemplated.<br />

6.4 Training Plan<br />

An individual training plan should be drawn up for each person carrying out<br />

maintenance on mobile cranes. This plan should take into account previous<br />

experience, qualifications <strong>and</strong> underpinning knowledge. Particular care should be<br />

taken where trainees fall into the category <strong>of</strong> Young Persons.<br />

Achievement <strong>of</strong> this plan <strong>and</strong> continuing pr<strong>of</strong>essional development should be<br />

monitored at frequent intervals as part <strong>of</strong> the management review process (See 10.0)<br />

<strong>and</strong> included in the quality system (e.g. ISO 9001) auditing process.<br />

The plan could include elements from the NVQ in Construction Plant <strong>Maintenance</strong>,<br />

Levels 1, 2 & 3.<br />

6.5 Continuing Pr<strong>of</strong>essional Development<br />

Continuing pr<strong>of</strong>essional development is the conscious updating <strong>of</strong> technical<br />

knowledge <strong>and</strong> the improvement <strong>of</strong> a maintenance person’s skill throughout their<br />

18


working life. This is a joint responsibility between the maintenance person <strong>and</strong> their<br />

employer.<br />

The employer should maintain a training, experience <strong>and</strong> development record for<br />

each maintenance person. The Record should include details <strong>of</strong> how ongoing<br />

development is being achieved <strong>and</strong> should include for example:<br />

� Initial training (See 6.8 Training Records);<br />

� Specific training towards enhancements/additions to skills;<br />

� Familiarisation/re-familiarisation, coaching <strong>and</strong> training;<br />

� Changes in legislation <strong>and</strong> working practices;<br />

� Updating <strong>of</strong> product knowledge;<br />

� Attendance at seminars <strong>and</strong> any refresher training courses.<br />

6.6 Manufacturer’s Technical Product Training<br />

Before carrying out maintenance on a specific make <strong>and</strong> model <strong>of</strong> mobile crane,<br />

where a trained supervisor is not present, all maintenance personnel must receive<br />

technical training from the crane or component manufacturer. If direct training by the<br />

manufacturer is not available, training may be carried out in-house. In this case<br />

training must be carried out by a competent trainer (definition) who has received<br />

model specific technical training directly from the manufacturer. This ensures that the<br />

source <strong>of</strong> such training is only once removed from the manufacturer.<br />

In the situation where the manufacturer no longer exists, a careful selection <strong>of</strong><br />

alternative competent training providers will be required.<br />

6.7 Qualifications <strong>and</strong> Assessment<br />

It is important that all maintenance personnel are regularly assessed to ensure that<br />

they can carry out their duties safely <strong>and</strong> effectively. An in-house assessment should<br />

be undertaken <strong>of</strong> all maintenance personnel on appointment <strong>and</strong> at regular intervals<br />

thereafter. Assessment should form part <strong>of</strong> any training.<br />

National Vocational Qualifications (NVQ) are available for construction plant<br />

maintenance. See Annex 11.<br />

6.8 Training Records<br />

A comprehensive individual training record should be established for all maintenance<br />

personnel. This should be updated as training is undertaken <strong>and</strong> as a minimum<br />

should include:<br />

� When the training took place;<br />

� Where the training took place;<br />

� The scope <strong>of</strong> the training;<br />

� The duration <strong>of</strong> the training;<br />

� Who delivered the training;<br />

� The result <strong>of</strong> any assessment;<br />

� When refresher training is required.<br />

19


7.0 Information for <strong>Maintenance</strong><br />

7.1 Introduction<br />

The wide variation <strong>of</strong> designs <strong>and</strong> the increasing complexity <strong>of</strong> mobile crane<br />

technology make it essential that all maintenance personnel are supplied with<br />

adequate information to enable them to carry out their duties effectively <strong>and</strong> safely.<br />

<strong>Maintenance</strong> information comes in various forms <strong>and</strong> from several sources.<br />

<strong>Mobile</strong> crane owners must ensure that a robust system is in place to provide<br />

adequate up to date information to maintenance personnel. This may be achieved in<br />

a number <strong>of</strong> ways including:-<br />

� Provision <strong>of</strong> paper manuals using a system which will ensure frequent<br />

updating is taking place;<br />

� Provision <strong>of</strong> electronic manuals using a system which will ensure frequent<br />

updating is taking place;<br />

� A central technical information function which can be contacted for up to date<br />

information whenever maintenance is taking place.<br />

NOTE: It is essential that a system is in place to ensure that manual updates, safety alerts<br />

<strong>and</strong> other information are communicated speedily to those who need to know.<br />

7.2 Manufacturer’s Information<br />

Information supplied by the mobile crane manufacturer will be the main source <strong>of</strong><br />

instructions <strong>and</strong> specifications when carrying out maintenance. The primary<br />

document will be the maintenance manual for the specific crane model (<strong>and</strong> in some<br />

cases serial number), supplemented by technical information bulletins.<br />

Care should be taken to ensure that the information is up to date <strong>and</strong> relevant to the<br />

crane on which maintenance is being carried out.<br />

Manufacture’s manuals are not always complete <strong>and</strong> in the case where a particular<br />

task is not covered, the manufacturer must be contacted for information BEFORE the<br />

task is undertaken. Manuals may not always contain an appropriate maintenance<br />

regime for older cranes, in which case the specific advice <strong>of</strong> the manufacturer should<br />

be sought.<br />

When purchasing a second h<strong>and</strong> crane care should be taken to ensure that any<br />

manuals supplied with the crane are appropriate for the specific model <strong>of</strong> crane.<br />

Some mobile crane manuals <strong>and</strong> other information are available to download from<br />

the manufacturer’s web site.<br />

7.3 In-House Technical Information<br />

Some mobile crane owners will have their own technical information dealing with<br />

specific issues relating to the cranes in their fleet. This can be a useful source <strong>of</strong><br />

information for maintenance personnel but care should be taken to ensure that<br />

information is current <strong>and</strong> obsolete data has been withdrawn.<br />

7.4 Method Statements <strong>and</strong> Work Instructions<br />

Much maintenance work on mobile cranes is <strong>of</strong> a routine nature <strong>and</strong> can be covered<br />

by generic risk assessments, method statements <strong>and</strong> work instructions. On<br />

occasions however, unusual <strong>and</strong> potentially hazardous tasks, will have to be<br />

undertaken. Such tasks must be planned thoroughly <strong>and</strong> a job specific safe system<br />

20


<strong>of</strong> work (risk assessment, method statement <strong>and</strong> briefing) put in place. This planning<br />

must include consideration <strong>of</strong> falling object hazards (h<strong>and</strong> tools, components etc.).<br />

This system <strong>of</strong> work must be described in a brief, focused job specific method<br />

statement on which all members <strong>of</strong> the maintenance team undertaking the task must<br />

be fully briefed. This briefing, which should be recorded, should concentrate on the<br />

task to be undertaken <strong>and</strong> highlight any unusual features <strong>of</strong> the job.<br />

7.5 Generic Information<br />

<strong>Maintenance</strong> personnel may also need to refer to generic information such as<br />

st<strong>and</strong>ards <strong>and</strong> industry guidance. For example, for wire ropes there are BS ISO<br />

4309: <strong>Cranes</strong> – Wire Ropes – Care, maintenance, installation, examination <strong>and</strong><br />

discard <strong>and</strong> wire rope manufacturer’s literature (See Bibliography).<br />

Care should be taken to ensure that the information is up to date.<br />

7.6 Machine History<br />

The history <strong>of</strong> the repairs <strong>and</strong> maintenance carried out on a mobile crane is <strong>of</strong>ten<br />

very helpful when trying to diagnose faults <strong>and</strong> repeated failures. <strong>Maintenance</strong><br />

personnel should be encouraged to contact their manager or supervisor to request<br />

relevant machine history details when appropriate.<br />

7.7 Information Formats<br />

Paper information such as manuals <strong>and</strong> bulletins is rapidly being replaced by<br />

electronic formats such as CD-ROM <strong>and</strong> website downloads. This has the advantage<br />

that physical storage space is kept to a minimum <strong>and</strong>, in the case <strong>of</strong> website<br />

downloads; information should be up to date at the point <strong>of</strong> access. However the use<br />

<strong>of</strong> electronic display devices, such as laptop computers, during maintenance is not<br />

always easy or practical. Information may therefore have to be printed out for use on<br />

site, in which case care should be taken that for any subsequent use the data is still<br />

current <strong>and</strong> relevant.<br />

7.8 Management <strong>of</strong> Information<br />

Information should be managed effectively if it is to be <strong>of</strong> maximum benefit to those<br />

involved in the maintenance process. Outdated information can at best waste time<br />

<strong>and</strong> at worst may well affect safety. It is therefore essential that organisations<br />

carrying out maintenance on mobile cranes ensure that they have robust systems<br />

<strong>and</strong> procedures to ensure that maintenance personnel are supplied with adequate<br />

information that is both up to date <strong>and</strong> accurate. The crane manufacturer should be<br />

consulted to ensure that information is current.<br />

21


8.0 <strong>Inspection</strong> During <strong>Maintenance</strong><br />

8.1 Introduction<br />

<strong>Inspection</strong> forms a very important part <strong>of</strong> the maintenance process <strong>and</strong> is required by<br />

the Health <strong>and</strong> Safety at Work Act (Section 2 (2) (a)); PUWER (Regulation 6) <strong>and</strong><br />

LOLER (Regulation 9 (3) (b)).<br />

The Guidance on Regulation 9 (3) (b) <strong>of</strong> LOLER says that:-<br />

You should arrange for suitable inspections to be carried out where the lifting equipment is <strong>of</strong><br />

a type where its safe operation is dependent on its condition in use <strong>and</strong> deterioration would<br />

lead to significant risks to the operator or other persons. In determining the suitability <strong>and</strong><br />

scope <strong>of</strong> the inspection you should refer to available information such as the manufacturer’s<br />

instructions. Examples <strong>of</strong> conditions which can be detected by inspection <strong>of</strong> the lifting<br />

equipment include:<br />

(a) rapid wear arising from use in an arduous environment, e.g. construction;<br />

(b) failure through repeated operation, e.g. [<strong>of</strong> a hoist winch brake];<br />

(c) malfunction, e.g. <strong>of</strong> a rated capacity indicator; <strong>and</strong><br />

(d) tampering with safety devices, e.g. [overriding a luffing limit].<br />

8.2 <strong>Inspection</strong> Intervals<br />

In-Service inspections <strong>of</strong> mobile cranes are normally <strong>of</strong> four types:-<br />

Daily Pre-use<br />

Checks<br />

Weekly<br />

<strong>Inspection</strong><br />

In-Service<br />

<strong>Maintenance</strong><br />

<strong>Inspection</strong><br />

Intermediate<br />

<strong>Inspection</strong><br />

Normally carried out by the mobile crane operator who<br />

should have been trained <strong>and</strong> assessed to carry out this<br />

task. Any defects found should be reported to his supervisor<br />

<strong>and</strong> formally recorded (See 8.3).<br />

Normally carried out by the operator if they have been<br />

assessed as trained <strong>and</strong> competent.<br />

Normally carried out by maintenance personnel as part <strong>of</strong><br />

the maintenance process (See 5.3).<br />

An additional inspection required to monitor deterioration <strong>of</strong><br />

a frequently failing or suspect component. (See 5.3)<br />

These checks <strong>and</strong> inspections should only be carried out by personnel who have<br />

been adequately trained <strong>and</strong> assessed as competent to carry out the required tasks.<br />

It is essential that the results <strong>of</strong> all checks <strong>and</strong> inspections are recorded in writing to<br />

ensure that the requirements <strong>of</strong> LOLER <strong>and</strong> PUWER are met.<br />

8.3 Reporting <strong>of</strong> Defects<br />

There must be provision for the operator(s) <strong>of</strong> mobile cranes to make written reports<br />

<strong>of</strong> defects or observations immediately they are identified.<br />

This facility must augment the normal verbal reporting that routinely takes place<br />

between operator <strong>and</strong> owner/manager. The written report should be to a pre-defined<br />

format, (a company pro-forma, a section on the daily time sheet, etc), which requests<br />

details <strong>of</strong> the defect or observation <strong>and</strong> supporting information such as date, time,<br />

crane identification, error codes, circumstances, etc., <strong>and</strong> must be reported at least<br />

daily. ‘Nil Reports’ must also be submitted at least daily.<br />

22


All the defect reports, including the ‘nil reports’, should be forwarded to the crane<br />

owner, (or the delegated person), who is in a position to make an informed decision<br />

about a planned response to the report. A copy <strong>of</strong> the original report should be<br />

retained by the operator.<br />

Once the defect / observation has been responded to <strong>and</strong> cleared this should then be<br />

recorded with supporting information on the original defect report.<br />

The ‘un-cleared’ <strong>and</strong> ‘cleared’ reports should be securely lodged within the crane<br />

owning company’s maintenance management system <strong>and</strong> must be made accessible<br />

on - dem<strong>and</strong> to the operators <strong>of</strong> the crane as well as other authorised bodies.<br />

8.4 Use <strong>of</strong> Checklists<br />

The use <strong>of</strong> check lists is extremely useful when carrying out inspections, both as a<br />

reminder <strong>of</strong> the items to be checked <strong>and</strong> as a means <strong>of</strong> recording the results <strong>of</strong> the<br />

inspection. When inspections are being carried out as part <strong>of</strong> maintenance it is<br />

important that maintenance personnel do not succumb to the temptation not to record<br />

faults that are then rectified as part <strong>of</strong> the maintenance process. This masking <strong>of</strong><br />

faults invalidates the machine history <strong>and</strong> hinders the review process (See Section<br />

10). Examples <strong>of</strong> daily check <strong>and</strong> weekly inspection checklists are given at Annex 6.<br />

An example <strong>of</strong> a typical in-service maintenance schedule is given at Annex 5. These<br />

checklists should only be taken as a general guide <strong>and</strong> may well need additions for<br />

specific models <strong>of</strong> mobile crane.<br />

NOTE: Additional information on inspection during maintenance is given in:-<br />

BS 7121- 2:2003 - Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 2: <strong>Inspection</strong>, testing <strong>and</strong><br />

examination<br />

8.5 Clearance <strong>of</strong> Defects<br />

It is important that defects identified during checks <strong>and</strong> inspections are classified <strong>and</strong><br />

rectified before they can affect the safety <strong>of</strong> persons. It is helpful to categorise<br />

defects as follows:-<br />

� defects affecting the safety <strong>of</strong> persons that are to be remedied immediately;<br />

� defects that are to be remedied prior to the next maintenance activity;<br />

� defects that are to be remedied at the next maintenance activity.<br />

The rectification <strong>of</strong> all defects identified must be recorded as evidence that the work<br />

has been carried out.<br />

A system should be in place to ensure that a crane cannot be used if safety critical<br />

defects have not been rectified.<br />

NOTE: Where cranes are on long term hire there is a need for sites to allocate time for<br />

routine inspection <strong>and</strong> maintenance. It is unreasonable for a site to expect this work to be<br />

undertaken overnight, in darkness, or always at weekends. Time needs to be built into normal<br />

working hours for this work. (See Section 10)<br />

23


9.0 <strong>Maintenance</strong> Records<br />

9.1 Introduction<br />

Comprehensive maintenance records are essential to the safe, efficient <strong>and</strong><br />

economical operation <strong>of</strong> mobile cranes. They provide a complete “cradle to grave”<br />

history <strong>of</strong> the individual crane giving the following benefits:-<br />

� evidence <strong>of</strong> adequate maintenance as part <strong>of</strong> the management system;<br />

� establishing breakdown trends over time <strong>and</strong> providing information for the<br />

review <strong>of</strong> maintenance frequency;<br />

� identification <strong>of</strong> component failure trends for feedback to the manufacturer;<br />

� evidence <strong>of</strong> adequate maintenance to the Enforcing Authorities in the event<br />

<strong>of</strong> an incident;<br />

� enabling the performance <strong>of</strong> the crane to be reviewed over time to inform<br />

future purchases.<br />

9.2 <strong>Maintenance</strong> Record Format<br />

<strong>Maintenance</strong> records can be kept in either paper or electronic format. Paper records<br />

are <strong>of</strong>ten easier to update as the input will <strong>of</strong>ten be in paper format such as<br />

inspection reports or work sheets. Electronic records are however more secure<br />

against loss <strong>and</strong> damage, <strong>and</strong> the data is more readily analysed. There are many<br />

maintenance record s<strong>of</strong>tware packages on the market but care should be taken when<br />

considering purchase to ensure that the system is flexible enough to accommodate<br />

changes in types <strong>of</strong> input <strong>and</strong> output.<br />

9.3 Machine History Files<br />

Each mobile crane should have its own machine history file, in either paper or<br />

electronic format, in which all records <strong>of</strong> maintenance activities are kept by the<br />

mobile crane owner. These should include (where applicable):-<br />

� EC Declaration <strong>of</strong> Conformity;<br />

� Service reports <strong>and</strong> worksheets;<br />

� Breakdown reports <strong>and</strong> worksheets;<br />

� Daily <strong>and</strong> weekly inspection reports;<br />

� Records <strong>of</strong> component replacement;<br />

� Records <strong>of</strong> major overhaul;<br />

� Test reports;<br />

� Wire rope <strong>and</strong> hook test certificates;<br />

� <strong>Thorough</strong> <strong>Examination</strong> reports;<br />

� Records <strong>of</strong> defect rectification;<br />

� Data logger records;<br />

� Records <strong>of</strong> supplementary tests;<br />

� Record <strong>of</strong> modifications <strong>and</strong> upgrades;<br />

� Safety Alerts from manufacturers;<br />

� Records <strong>of</strong> extraordinary events<br />

24


� Records <strong>of</strong> unusual applications.<br />

Where a mobile crane is on site for an extended period the user will need to be able<br />

to demonstrate that the crane has been adequately maintained (PUWER Reg. 5).<br />

The user should ensure that they obtain sufficient evidence from the crane owner to<br />

demonstrate this.<br />

25


10.0 Management Review <strong>of</strong> <strong>Maintenance</strong> Records <strong>and</strong> Procedures<br />

10.1 Introduction<br />

A regular management review <strong>of</strong> mobile crane maintenance records <strong>and</strong> procedures<br />

is essential for the safe <strong>and</strong> efficient operation <strong>of</strong> a mobile crane fleet. It ensures that<br />

management can be confident that a robust maintenance system is in place <strong>and</strong> will<br />

rapidly highlight any shortcomings <strong>and</strong> the need for corrective action. The review<br />

should include:-<br />

� A review to see that faults are being corrected <strong>and</strong> closed out appropriately<br />

<strong>and</strong> maintenance schedule is being completed to plan;<br />

� A review to determine if the regime <strong>and</strong> frequencies are appropriate <strong>and</strong> to<br />

analyse trends.<br />

10.2 Benefits<br />

The benefits <strong>of</strong> regular management review <strong>of</strong> maintenance records are:-<br />

� Confidence that the system is functioning correctly;<br />

� Identification <strong>of</strong> extraordinary events <strong>and</strong> failures;<br />

� Ensuring that there is evidence <strong>of</strong> adequate maintenance to the Enforcing<br />

Authorities in the event <strong>of</strong> an incident;<br />

� Establishing breakdown trends over time <strong>and</strong> informing the review <strong>of</strong><br />

maintenance frequency;<br />

� Identification <strong>of</strong> component failure trends for feedback to the manufacturer;<br />

� Providing breakdown trends to the manufacturer to inform future designs;<br />

� Highlighting on-site maintenance access problems for feedback to the<br />

manufacturer to improve future designs;<br />

� Monitoring the performance <strong>of</strong> individual cranes over time to provide<br />

information on future purchases.<br />

10.3 Review Frequency<br />

The review should be carried out initially at least monthly. Once a suitable level <strong>of</strong><br />

confidence in the systems has been established the review frequency may be<br />

reduced in the light <strong>of</strong> experience.<br />

10.4 Review Methodology<br />

The review should aim to identify exceptional events such as occurrences <strong>of</strong> heavy<br />

expenditure <strong>and</strong> reoccurring faults. It should also measure achievement <strong>of</strong><br />

maintenance activities against target. An example <strong>of</strong> the use <strong>of</strong> such Key<br />

Performance Indicators is given in Annex 9.<br />

10.5 Review Records<br />

It is essential that written records <strong>of</strong> the management review are made, both as<br />

evidence that the reviews have been undertaken <strong>and</strong> to evaluate long term trends.<br />

26


11.0 Site Issues For <strong>Maintenance</strong><br />

11.1 Introduction<br />

Maintaining a mobile crane on site presents a particular set <strong>of</strong> issues when compared<br />

with carrying out maintenance operations in a workshop or yard. These issues are<br />

best addressed at the planning stage before the crane is set up on site <strong>and</strong> taken into<br />

use. The effective maintenance <strong>of</strong> mobile cranes on site will require the cooperation<br />

<strong>of</strong> the user <strong>and</strong> an example <strong>of</strong> a document informing them <strong>of</strong> the issues they should<br />

consider when maintenance is being undertaken, is given at Annex 4.<br />

11.2 <strong>Maintenance</strong> Downtime<br />

The main purpose for a mobile crane being on site is to carry out lifting operations.<br />

Site managers are underst<strong>and</strong>ably reluctant to stop the crane whilst maintenance is<br />

carried out. If maintenance downtime is not scheduled into the programme,<br />

maintenance is pushed to the back <strong>of</strong> the queue <strong>and</strong> ends up being carried out<br />

hurriedly in unsafe conditions such as poor light.<br />

It is therefore essential that mobile crane owners make clear to those hiring their<br />

cranes that maintenance is <strong>of</strong> paramount importance <strong>and</strong> that adequate maintenance<br />

downtime must be built into the programme. Hirers must be informed at the planning<br />

stage <strong>of</strong> the frequency <strong>and</strong> length <strong>of</strong> time required for maintenance operations. In<br />

certain circumstances it may be <strong>of</strong> benefit to substitute another crane to allow<br />

maintenance to be carried out in a workshop, rather than on site.<br />

Projects in built up areas <strong>of</strong>ten have environmental restrictions imposed on them<br />

which severely limit working time at week ends <strong>and</strong> evenings. Such restrictions must<br />

be taken into account in maintenance planning.<br />

<strong>Mobile</strong> crane hirers should be informed that when maintenance <strong>of</strong> a mobile crane is<br />

taking place the maintenance team have full control <strong>of</strong> the mobile crane.<br />

11.3 Site Inductions<br />

<strong>Maintenance</strong> personnel should have undertaken suitable <strong>and</strong> sufficient health <strong>and</strong><br />

safety training applicable to their activity before arriving on site. Such training should<br />

be sanctioned by an appropriate industry body for the work function being carried<br />

out. (e.g. CPCS Health <strong>and</strong> Safety test). To supplement their trade specific health<br />

<strong>and</strong> safety training, visiting personnel must attend an appropriate site specific safety<br />

induction focused on the specific hazards that may be present in the vicinity <strong>of</strong> the<br />

intended work,<br />

The induction must be <strong>of</strong> sufficient length to cover the relevant risks, however it is<br />

anticipated that it would normally take 20 – 30 min, <strong>and</strong> where necessary be<br />

specifically prepared by the Principal Contractor in control <strong>of</strong> the site. The time <strong>of</strong> the<br />

induction should be agreed in advance. If the maintenance work is programmed to<br />

commence at 8 am, there will be an automatic delay if the induction does not start<br />

until 9 or 10 am. The induction should be given by the Principal Contractor’s Manager<br />

who will oversee the maintenance activity. This will help build relationships <strong>and</strong> a<br />

joint underst<strong>and</strong>ing. Where necessary the induction should be followed by a methods<br />

briefing talk given by the crane company supervisor to the maintenance team, but<br />

also attended by the Principal Contractors Management, <strong>and</strong> any other parties<br />

involved i.e. security guards, those arranging exclusion zones or traffic diversions<br />

etc. This is to help ensure all know what is to happen, when <strong>and</strong> by whom.<br />

27


11.4 Communication<br />

Those planning <strong>and</strong> carrying out maintenance on mobile cranes on site must ensure<br />

that they have effective lines <strong>of</strong> communication with the site for both routine<br />

maintenance <strong>and</strong> attending to breakdowns. <strong>Maintenance</strong> personnel must always<br />

report their arrival on site, agree the programme <strong>of</strong> work to be carried out <strong>and</strong> report<br />

back once the tasks have been completed. This will avoid much frustration <strong>and</strong><br />

misunderst<strong>and</strong>ing on both sides.<br />

11.5 Availability <strong>of</strong> Operators<br />

Many maintenance operations require the crane to be operated from the control cab<br />

whilst maintenance personnel are working on other parts <strong>of</strong> the crane. Arrangements<br />

should be made to ensure that an operator is available on such occasions <strong>and</strong> that a<br />

safe system <strong>of</strong> work is in place.<br />

11.6 Availability <strong>of</strong> Site Facilities<br />

When maintenance is being carried both during <strong>and</strong> outside normal working hours,<br />

arrangements must be made to ensure that site management, safety <strong>and</strong> welfare<br />

facilities are available to maintenance personnel.<br />

11.7 Lone Working<br />

Lone working should be avoided at all times by suitable liaison with the person in<br />

control <strong>of</strong> the site to ensure that site personnel are always in attendance.<br />

The planning process for work at height on mobile cranes should take into account<br />

the particular hazards <strong>of</strong> lone working <strong>and</strong> maintenance at height by lone workers<br />

should not be undertaken.<br />

If lone working at ground level is unavoidable suitable measures should be put in<br />

place to minimise risks to the lone worker. This might include:-<br />

� Call in arrangements;<br />

� Notification to a remote supervisor <strong>of</strong> entry <strong>and</strong> exit to premises;<br />

� Provision <strong>of</strong> alarm <strong>and</strong> tracking systems.<br />

NOTE: Additional advice on lone working is given in HSE publication INDG 73 - Working<br />

alone in safety<br />

11.8 Work at Height<br />

Some maintenance activities on mobile cranes will require competent persons to<br />

work at height outside edge protected areas on the mobile crane structure. The Work<br />

at Height Regulations 2005 set out a hierarchy <strong>of</strong> fall protection measures to be<br />

taken when planning work at height. These are illustrated in the following diagram:-<br />

28


This means that those planning work at height on mobile cranes should:-<br />

� Avoid work at height wherever possible <strong>and</strong> actively seek solutions to<br />

facilitate this;<br />

� If this is not possible, use “collective” means <strong>of</strong> protection such as guardrails;<br />

� If this is not possible, use “personal” means <strong>of</strong> prevention such as work<br />

restraint;<br />

� If this is not possible, use a personal fall protection system such as a work<br />

positioning system or fall arrest system;<br />

� Additionally provide training <strong>and</strong> instruction or take other measures to prevent<br />

any person falling a distance liable to cause personal injury.<br />

Where a risk assessment indicates that a personal fall protection system is required<br />

a work positioning system should always be used in preference to a fall arrest<br />

system. Where the use <strong>of</strong> fall arrest personal fall protection systems are unavoidable<br />

there will be a risk <strong>of</strong> the wearer being left suspended following a fall <strong>and</strong><br />

arrangements must be made to ensure that they can be rescued in a safe <strong>and</strong> timely<br />

manner (See Annex 1).<br />

Where work is being carried out on mobile tower cranes suitable <strong>and</strong> sufficient<br />

arrangements must be put in place for the rescue <strong>of</strong> personnel from height. This<br />

matter is dealt with in the CPA Technical Information Note TIN 013 - Rescue <strong>of</strong><br />

Personnel from height on Tower <strong>Cranes</strong> which may be downloaded from the CPA<br />

web site.<br />

11.9 Isolation <strong>of</strong> Systems During <strong>Maintenance</strong><br />

To avoid the risk <strong>of</strong> trapping, crushing <strong>and</strong> shearing during the maintenance <strong>of</strong><br />

mechanisms on mobile cranes, all systems should be isolated before work starts.<br />

Where this is not possible due to the need to have power to a system for fault<br />

diagnosis etc., a safe system <strong>of</strong> work should be put in place to mitigate the risks <strong>of</strong><br />

trapping. Such a safe system <strong>of</strong> work may well involve a “permit to work” <strong>and</strong><br />

adequate communication between the crane operator <strong>and</strong> other members <strong>of</strong> the<br />

maintenance team. If safety systems have to be bridged or over-ridden during the<br />

fault finding, checks must be made to ensure that all safety systems are functioning<br />

correctly before the crane is returned to service.<br />

11.10 Exclusion Zones<br />

Where maintenance is being carried out on site <strong>and</strong> there is a risk <strong>of</strong> falling objects, a<br />

suitable exclusion zone should be established <strong>and</strong> enforced around the crane to<br />

provide protection from falling objects.<br />

11.11 Communication Equipment<br />

<strong>Maintenance</strong> personnel should be provided with an adequate means <strong>of</strong><br />

communication, <strong>of</strong>ten h<strong>and</strong> portable radios, to ensure that all members <strong>of</strong> the<br />

maintenance team can communicate effectively with each other, the mobile crane<br />

operator <strong>and</strong> personnel on the ground.<br />

NOTE: Additional advice on radio communications is given in the CPA Technical Information<br />

Note TIN 017 - Radio Communication for Lifting Operations<br />

29


12.0 Spare Parts<br />

12.1 Introduction<br />

<strong>Maintenance</strong> operations on mobile cranes can only be fully effective if the correct<br />

spare parts are available at the correct location in a timely manner. This can only be<br />

achieved if a robust spare parts management system is in place. Ineffective<br />

management <strong>of</strong> spare parts will result in both direct <strong>and</strong> indirect costs <strong>and</strong> may well<br />

affect the safety <strong>of</strong> the mobile crane.<br />

12.2 Availability <strong>and</strong> Sourcing<br />

The two extremes <strong>of</strong> spare part sourcing are to stock every spare part that could ever<br />

be required in the crane owner’s stores or to stock nothing, relying on the mobile<br />

crane manufacturer’s stock with courier delivery. In practice a combination <strong>of</strong> the two<br />

is <strong>of</strong>ten used, avoiding a costly inventory whilst ensuring that fast moving items are<br />

readily available.<br />

A list <strong>of</strong> critical items with long lead times should be identified by consultation with the<br />

manufacturer. Strong consideration should be given to stocking such items to ensure<br />

minimum crane downtime.<br />

12.3 Spare Part Specification<br />

Spare parts must always meet the crane manufacturer’s specification. Ensuring that<br />

this is the case is <strong>of</strong>ten a complex process involving a full engineering assessment <strong>of</strong><br />

the component to be replaced <strong>and</strong> it is <strong>of</strong>ten easier to purchase from the crane<br />

manufacturer. One <strong>of</strong> the benefits <strong>of</strong> purchase from the crane manufacturer is<br />

ensuring that parts are to the latest specification.<br />

12.4 Stock Control<br />

Spare parts must be controlled using a robust stock control system. This will allow<br />

stock levels to be maintained at economic levels <strong>and</strong> ensure that valuable stock is<br />

not “mislaid”. Too much stock will tie up capital unnecessarily, whilst too little will<br />

result in excessive downtime <strong>and</strong> repeat visits to site.<br />

Stock levels should be periodically reviewed to ensure that levels are adjusted in the<br />

light <strong>of</strong> experience <strong>and</strong> that items with limited shelf life are identified <strong>and</strong> disposed <strong>of</strong><br />

as required.<br />

12.5 Storage <strong>and</strong> Identification<br />

Spare parts must be stored in secure dry conditions to minimise deterioration <strong>and</strong><br />

loss. Some form <strong>of</strong> storage system is essential in order that each part has unique<br />

location to ensure that parts can be easily located for issue <strong>and</strong> stock checks. Each<br />

individual part must be identifiable by part number <strong>and</strong> batch/purchase number (if<br />

applicable) to ensure that they are readily identifiable in storage, in the workshop <strong>and</strong><br />

on site. Identification solely by comparison with the part being replaced is dangerous<br />

<strong>and</strong> could result in a component with the wrong material specification or dimension<br />

being fitted. Some parts such as hoses will have a limited shelf life <strong>and</strong> this must be<br />

taken into account in the storage system.<br />

Spare parts can represent a considerable capital investment <strong>and</strong> should be treated<br />

as tangible business assets.<br />

If spare parts are stocked in service vans for ready availability on site, this stock must<br />

be subject to regular audit to ensure that items are not mislaid <strong>and</strong> that they are in<br />

30


“as new” condition. Care should be taken to ensure that maintenance personnel do<br />

not accumulate a personal stock <strong>of</strong> part worn components (See 12.6).<br />

12.6 Component Reuse <strong>and</strong> Refurbishment<br />

There is always the temptation to store part worn components for re-use. This will be<br />

accompanied by safety risks as these components may contain hidden defects <strong>and</strong><br />

may fail prematurely <strong>and</strong> without warning. Furthermore their provenance <strong>and</strong><br />

previous utilisation can be confused or completely lost.<br />

Refurbishment <strong>of</strong> previously-used parts must be undertaken with care, with thorough<br />

working quality management <strong>and</strong> process quality controls:<br />

� All parts should carry a unique serial number or marking for traceability.<br />

� The refurbishment <strong>of</strong> any parts should be undertaken to bring back those<br />

parts back to the original manufacturer’s specifications.<br />

� The specification <strong>of</strong> component to be refurbished must be fully understood<br />

by the re-furbisher. This includes any subsequent changes to the original<br />

specification which may have been incorporated by the manufacturer in<br />

the light <strong>of</strong> service experience.<br />

� Parts being considered for refurbishment must be inspected thoroughly<br />

including, where necessary, metallurgical examinations, to confirm their<br />

suitability for refurbishment <strong>and</strong> re-use.<br />

� Where there is any doubt or uncertainty about the provenance or previous<br />

utilisation <strong>of</strong> the part, for example if it might have previously taken a shock<br />

load, then the advice <strong>of</strong> the original manufacturer should be sought <strong>and</strong><br />

suitable inspection <strong>and</strong> testing completed.<br />

� The refurbishment must be carried out by companies with demonstrable<br />

competence in the type <strong>of</strong> work <strong>and</strong> auditable <strong>and</strong> operating robust quality<br />

management systems. An example being ISO9001<br />

� An audit trail <strong>of</strong> refurbishment documentation must be maintained by the<br />

crane owner.<br />

Worn, failed <strong>and</strong> otherwise replaced parts that are to be further examined must be<br />

stored in controlled <strong>and</strong> quarantined area with full documentation. Once the decision<br />

has been to dispose <strong>of</strong> parts they should be destroyed before scrapping in a manner<br />

that precludes any repair that might make them suitable for re-use.<br />

All other parts that become surplus after replacement should be immediately<br />

destroyed before scrapping in a similar manner.<br />

12.7 Installation <strong>and</strong> Replacement <strong>of</strong> Spare Parts<br />

Spare parts must always be installed in accordance with manufacturer’s instructions<br />

by a competent <strong>and</strong> authorised person. If the competent person is unsure about<br />

procedure <strong>of</strong> fitting any new part, they should contact the manufacture for additional<br />

information. Instructions for the installation <strong>of</strong> spare parts are not normally given out<br />

with the supply <strong>of</strong> the parts, but are usually available from the manufacturer’s service<br />

department upon request.<br />

Special attention must be given to the replacement <strong>of</strong> parts that may be fitted to loadbearing<br />

components <strong>and</strong> pressurised components <strong>of</strong> the crane, as a dangerous<br />

occurrence could result from lack <strong>of</strong> knowledge or care.<br />

31


In all cases <strong>of</strong> programmable components, installation should only be carried out by a<br />

manufacturer’s field service engineer, as they will have access to all the data <strong>and</strong><br />

equipment to ensure the component is installed, <strong>and</strong> set up safely.<br />

.<br />

32


13.0 <strong>Maintenance</strong> Facilities <strong>and</strong> Equipment<br />

13.1 Introduction<br />

<strong>Maintenance</strong> operations on mobile cranes require adequate facilities <strong>and</strong> equipment<br />

to enable them to be carried out effectively, efficiently <strong>and</strong> safely. The size <strong>and</strong><br />

sophistication <strong>of</strong> the facilities will depend on the degree <strong>of</strong> maintenance tasks to be<br />

carried out.<br />

All tasks carried out during maintenance operations on mobile crane must only be<br />

undertaken following a suitable <strong>and</strong> sufficient risk assessment which identifies any<br />

control measures required to reduce risks to an acceptable level. The outcomes <strong>of</strong><br />

the risk assessment should be used to put a safe system <strong>of</strong> work in place. This safe<br />

system <strong>of</strong> work should be documented in a method statement, which may be generic<br />

for frequently repeated tasks (See 7.4). Control measures will include the training,<br />

assessment <strong>and</strong> authorisation <strong>of</strong> all personnel required to carry out the tasks <strong>and</strong><br />

may also include the provision <strong>of</strong> suitable Personnel Protective Equipment (PPE). If<br />

PPE is used personnel must be instructed in pre use checks, correct usage <strong>and</strong><br />

maintenance.<br />

<strong>Maintenance</strong> activities involving work at height must be planned <strong>and</strong> carried out in<br />

accordance with the following hierarchy.<br />

Additional information on work at height is given in Annex 1.<br />

13.2 Workshops<br />

If maintenance <strong>and</strong> overhaul <strong>of</strong> mechanical, hydraulic <strong>and</strong> electrical components <strong>and</strong><br />

assemblies is to be carried out successfully, an adequately sized workshop is<br />

essential. This should be weather tight with adequate heating, ventilation, lighting<br />

<strong>and</strong> lifting equipment; <strong>and</strong> provided with suitable services (power, air etc), work<br />

benches <strong>and</strong> adequate storage for tools <strong>and</strong> equipment.<br />

If workshops are provided with pits for working under crane chassis they must be<br />

provided with adequate ventilation, edge protection <strong>and</strong> waste oil facilities.<br />

13.3 Welfare Facilities<br />

Suitable welfare facilities should be provided for the use <strong>of</strong> all employees <strong>and</strong><br />

visitors. These should include:-<br />

33


� Toilets;<br />

� Washing facilities, including showers;<br />

� Clothes storage <strong>and</strong> drying;<br />

� Messing facilities;<br />

� First Aid facilities <strong>and</strong> arrangements.<br />

13.4 Washdown <strong>and</strong> Cleaning Area<br />

A suitable area should be allocated to the washing down <strong>and</strong> cleaning <strong>of</strong> mobile<br />

cranes <strong>and</strong> components. This should be a concrete area with suitable drainage which<br />

includes interceptors to ensure that solids <strong>and</strong> oils are not discharged into the main<br />

drainage system <strong>and</strong> meet local environmental regulations. It is important that<br />

interceptors <strong>and</strong> other equipment in this area are regularly maintained <strong>and</strong> records <strong>of</strong><br />

this kept. COSHH assessments should be carried out on any solvents, detergents etc<br />

used in this area.<br />

Active consideration should be given to the recycling <strong>of</strong> washdown water.<br />

13.5 Shot Blasting<br />

If shot blasting <strong>of</strong> mobile crane components is to be undertaken at the maintenance<br />

facility adequate facilities must be provided to ensure that the requirements <strong>of</strong> noise,<br />

pollution control <strong>and</strong> COSHH regulations are not breached.<br />

13.6 Spray painting<br />

If spray painting <strong>of</strong> mobile crane components is to be undertaken at the maintenance<br />

facility adequate facilities must be provided to ensure that the requirements <strong>of</strong> noise,<br />

pollution control <strong>and</strong> COSHH regulations are not breached. In certain circumstances<br />

spray painting operations will require licensing by the Local Authority who should be<br />

consulted before any spray painting equipment is installed at the maintenance<br />

facility.<br />

13.7 Waste Disposal<br />

<strong>Mobile</strong> crane maintenance operations may well produce various types <strong>of</strong> hazardous<br />

waste including waste oils, paint <strong>and</strong> thinners. These should be stored in appropriate<br />

containers <strong>and</strong> disposed <strong>of</strong> using a licensed waste contractor. Registration with the<br />

Environment Agency is also required <strong>and</strong> records kept.<br />

13.8 Hard St<strong>and</strong>ing<br />

In addition to covered workshops, maintenance facilities should be provided with<br />

adequate hard st<strong>and</strong>ing to enable mobile cranes <strong>and</strong> components to be moved,<br />

stored <strong>and</strong> h<strong>and</strong>led safely. The hard st<strong>and</strong>ing should have adequate load bearing<br />

capacity for the loads to be imposed.<br />

13.9 Test Area<br />

<strong>Maintenance</strong> facilities should be provided with a suitable test area to enable mobile<br />

cranes to be tested for correct functioning. This area should be <strong>of</strong> sufficient size to<br />

enable segregation from other activities. Additional information on test site<br />

conditions, test weights etc. is given in BS 7121-2:2003.<br />

34


13.10 Lifting Equipment<br />

<strong>Maintenance</strong> facilities will require adequate lifting equipment <strong>and</strong> lifting accessories<br />

to ensure that mobile crane components can be h<strong>and</strong>led safely both inside <strong>and</strong><br />

outside the workshop. Internal craneage is <strong>of</strong>ten provided by the installation <strong>of</strong> an<br />

overhead travelling crane, whilst lifting outside a workshop is frequently carried out<br />

using forklifts or mobile cranes.<br />

It is essential that all lifting equipment <strong>and</strong> lift accessories are subject to pre-use<br />

checks, preventive maintenance, inspection <strong>and</strong> <strong>Thorough</strong> <strong>Examination</strong>.<br />

13.11 Loading <strong>and</strong> Unloading <strong>of</strong> Components<br />

The loading <strong>and</strong> unloading <strong>of</strong> components may involve work at height by the<br />

personnel carrying out these operations. Suitable risk assessments should be carried<br />

out to identify both the hazards <strong>and</strong> suitable control measures. Control measures<br />

may well include the provision <strong>of</strong> access gantries <strong>and</strong> loading bays with suitable edge<br />

protection.<br />

NOTE: Further advice is given in the CPA Best Practice Guide on Work at Height Whilst<br />

Loading <strong>and</strong> Unloading Transport.<br />

13.12 Working Under <strong>Mobile</strong> <strong>Cranes</strong> Supported on Outriggers<br />

<strong>Mobile</strong> cranes are frequently supported on their outriggers whist undergoing<br />

maintenance, particularly when work is being carried out on axles, drive train<br />

components <strong>and</strong> braking systems. When working under mobile cranes supported on<br />

hydraulic outrigger jacks, steps, such as the use <strong>of</strong> baulk timbers, should be taken to<br />

protect personnel under the crane chassis in the event <strong>of</strong> a hydraulic failure.<br />

13.13 Wire Ropes<br />

Facilities should be provided for the storage, cutting, tensioning <strong>and</strong> lubrication <strong>of</strong><br />

wire ropes. Wire ropes should be stored <strong>and</strong> transported on suitable drums, not as<br />

loose coils <strong>and</strong> must be stored undercover in a well ventilated area. RA, MS <strong>and</strong> PPE<br />

NOTE: Further advice on the installation, inspection <strong>and</strong> maintenance <strong>of</strong> wire ropes is given<br />

in:<br />

� Clause 22 <strong>of</strong> BS 7121-1:2006, Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 1:<br />

General;<br />

� Clause 12 <strong>of</strong> BS 7121-2:2003, Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 2:<br />

<strong>Inspection</strong>, testing <strong>and</strong> examination;<br />

� CPA Technical Information Note TIN 004 - Installing Wire Ropes on Winch Drums<br />

<strong>and</strong> Storage Reels.<br />

13.14 Test <strong>and</strong> Measuring Equipment<br />

Sufficient test <strong>and</strong> measuring equipment must be available to enable all testing <strong>and</strong><br />

measurement to be carried out accurately. Such tests <strong>and</strong> measurements might<br />

include:-<br />

� Function testing;<br />

� Overload testing;<br />

� Electrical testing;<br />

� Fault diagnosis;<br />

35


� Non destructive testing;<br />

� Dimensional measurement;<br />

� Torque measurement;<br />

� Bearing play measurement;<br />

� Pressure <strong>and</strong> flow measurement (hydraulic <strong>and</strong> pneumatic).<br />

All test <strong>and</strong> measuring equipment should be marked with a unique identification<br />

number <strong>and</strong> entered on an asset register to ensure that the equipment can be<br />

monitored <strong>and</strong> tracked throughout its life. Equipment should be stored in a dry <strong>and</strong><br />

secure location.<br />

13.15 Calibration<br />

All test <strong>and</strong> measuring equipment should be subjected to periodic calibration to<br />

nationally traceable st<strong>and</strong>ards, marked with the calibration expiry date <strong>and</strong> records<br />

kept <strong>of</strong> the calibration. The calibration interval should be set taking into account<br />

manufacturer’s guidance together with the frequency <strong>and</strong> conditions <strong>of</strong> use.<br />

13.16 H<strong>and</strong> Tools<br />

All h<strong>and</strong> tools should be checked <strong>and</strong> maintained by the user at regular intervals to<br />

ensure that they continue to function safely. H<strong>and</strong> tools should also be checked at<br />

regular intervals by the supervisor.<br />

13.17 Power Tools<br />

<strong>Maintenance</strong> personnel should have access to adequate power tools to enable them<br />

to carry out maintenance tasks safely <strong>and</strong> efficiently. These tools should be checked<br />

<strong>and</strong> maintained at regular intervals to ensure that they continue to function safely.<br />

Electric power tools are required to be checked before each use by the user <strong>and</strong><br />

more formally (PAT tested) at regular intervals to ensure that they remain safe. In<br />

general power tools used on construction sites should be PAT tested at a maximum<br />

<strong>of</strong> three monthly intervals, whilst those used in a workshop or permanent<br />

establishment should be tested every six to twelve months. This will include chargers<br />

<strong>and</strong> inverters for cordless tools.<br />

NOTE: Further advice on the maintenance <strong>and</strong> testing <strong>of</strong> electrical power tools is given in<br />

HS(G) 107 - Maintaining portable <strong>and</strong> transportable electrical equipment.<br />

13.18 Welding Facilities<br />

Before undertaking welding on structural components, the crane manufacturer must<br />

be consulted,<br />

Welding on structural components should only be carried out by trained competent<br />

personnel working to welding procedures approved by the mobile crane<br />

manufacturer or following a full engineering assessment by a competent engineer.<br />

Welding should be carried out undercover wherever possible <strong>and</strong> arrangements<br />

should be made to protect welders <strong>and</strong> other personnel from arc flashes <strong>and</strong> welding<br />

fumes.<br />

Welding equipment should be regularly checked, maintained <strong>and</strong> calibrated as<br />

appropriate. Consumables should be stored in a secure dry area.<br />

Weld repairs should be subjected to full visual, <strong>and</strong> where appropriate NDT<br />

inspection.<br />

36


NOTE: Further information is given in:-<br />

� BS EN 287-1:2004 - Qualification test <strong>of</strong> welders. Fusion welding. Steels;<br />

� BS EN 970:1997 - Non-destructive examination <strong>of</strong> fusion welds. Visual examination;<br />

� BS EN ISO 15607:2003 – Specification <strong>and</strong> qualification <strong>of</strong> welding procedures for metallic<br />

materials. General rules;<br />

� British Institute <strong>of</strong> Non-destructive Testing at http://www.bindt.org.<br />

13.19 Hydraulic Presses<br />

The maintenance <strong>of</strong> some mobile cranes requires the use <strong>of</strong> hydraulic presses.<br />

These items should be checked <strong>and</strong> maintained as with other power tools.<br />

13.20 Job Control<br />

It is essential that all refurbishment <strong>and</strong> repair <strong>of</strong> mobile cranes is carried out by<br />

competent personnel who are fully briefed <strong>and</strong> supplied with adequate information,<br />

equipment <strong>and</strong> facilities. Jobs should be monitored to measure progress against<br />

target <strong>and</strong> to ensure that late delivery <strong>of</strong> spare parts, lack <strong>of</strong> resources etc. is not<br />

holding up the job.<br />

13.21 Repair Records<br />

It is essential that all work carried out as part <strong>of</strong> maintenance is recorded in the<br />

machine history file (See 9.3).<br />

13.22 <strong>Maintenance</strong> Vehicles<br />

<strong>Maintenance</strong> Personnel who are required to work on site should be provided with<br />

suitable vehicles for transport <strong>of</strong> themselves, tools, equipment <strong>and</strong> spare parts.<br />

Vehicles should have adequate carrying capacity <strong>and</strong> be fitted with racking to ensure<br />

that tools, equipment <strong>and</strong> parts can be stored securely during travelling <strong>and</strong> in the<br />

event <strong>of</strong> an impact. Overall security <strong>of</strong> the vehicle should also be considered as the<br />

contents may well have a high value. Vehicles carrying oils, compressed gases <strong>and</strong><br />

waste materials may need to comply with the requirements <strong>of</strong> the Carriage <strong>of</strong><br />

Dangerous Goods <strong>and</strong> Use <strong>of</strong> Transportable Pressure Equipment Regulations 2007,<br />

depending on the type <strong>of</strong> goods <strong>and</strong> quantities carried.<br />

Vehicles should also be provided with first aid kits <strong>and</strong> fire extinguishers <strong>and</strong> they<br />

drivers trained to use them.<br />

It should be remembered that although maintenance vehicles under 3500kg GVW<br />

are exempt from the EU Drivers Hours <strong>and</strong> Tachograph rules, anyone driving a<br />

company vehicle is “at work” <strong>and</strong> the requirements <strong>of</strong> the Working Time Regulations<br />

for rest breaks etc. apply.<br />

13.23 Tyre <strong>Maintenance</strong><br />

Tyres are designed to maintain a cushion <strong>of</strong> air between the vehicle <strong>and</strong> road surface<br />

<strong>and</strong> provides the final link between the wheel <strong>and</strong> road. They must:-<br />

� Cushion the vehicle, its load <strong>and</strong> the driver against road shocks;<br />

� Transmit to the road surface, both traction <strong>and</strong> braking forces in all weather<br />

condition;<br />

� Control the vehicle by its influence upon braking, acceleration <strong>and</strong> cornering<br />

forces;<br />

37


� Have a good resistance to abrasion in order to give good tyre wear;<br />

� Have maximum resistance to impact blows.<br />

In order for tyres to fulfil these requirements functions <strong>and</strong> perform safely, it is<br />

essential that the following care <strong>and</strong> maintenance procedures are employed at all<br />

times:-<br />

13.23.1 Tyre Pressures<br />

� Pressures should be checked weekly when the tyres are cold;<br />

� Personnel inflating tyres should st<strong>and</strong> a minimum <strong>of</strong> 3 metres between the<br />

nozzle <strong>and</strong> airline trigger mechanism;<br />

� Personnel should ensure that they st<strong>and</strong> facing the tread <strong>of</strong> the tyre when<br />

inflating;<br />

� Tyre valves should be checked to ensure that they are not leaking. High<br />

pressure valve caps should always be replaced.<br />

13.23.2 Flat Tyres<br />

� Any tyre found to be severely under inflated or deflated must be removed<br />

from the rim <strong>and</strong> checked out by an authorised dealer.<br />

13.23.3 Visual inspection<br />

� The tread <strong>and</strong> side walls should be checked for bulges <strong>and</strong> separation;<br />

� The tread <strong>and</strong> side walls should be checked for cuts;<br />

� All foreign objects caught in tread pattern should be removed:<br />

� Tread depths should be measured as part <strong>of</strong> a routine inspection programme<br />

<strong>and</strong> are required to meet the legal requirements <strong>of</strong> 1mm pattern depth, any<br />

tyres found below this limit must be replaced.<br />

13.23.4 Equipment Required for Tyre <strong>Maintenance</strong><br />

� A compressor capable <strong>of</strong> achieving the maximum operating tyre pressure.<br />

� An inline filter should be fitted to ensure all moisture is removed from the<br />

airline, thus preventing internal corrosion <strong>of</strong> the wheel rim <strong>and</strong> eventual<br />

sealing problems <strong>and</strong>/or loss <strong>of</strong> pressure.<br />

� A tyre pressure gauge which is certified accurate for the purpose <strong>of</strong><br />

maintaining the tyres at the correct pressure.<br />

NOTE: Further information is given in:-<br />

1. ECE Regulation 54 –specifies tyre type approval <strong>and</strong> is a legal requirement that all<br />

tyres fitted to vehicles first used after 01.04.1991 must be approved to this regulation.<br />

2. BS AU 159 - St<strong>and</strong>ard covering the repair <strong>of</strong> pneumatic tyres<br />

3. BS AU 144 – St<strong>and</strong>ard for the manufacturing <strong>of</strong> remoulded tyres.<br />

4. C&U Regs – The Road Vehicle (Construction <strong>and</strong> Use) Regulations 1986 (as<br />

amended) this is the main regulations for the use <strong>of</strong> vehicles on the road.<br />

13.24 Working Time<br />

38


The Working Time Regulations limit the maximum number <strong>of</strong> hours that an employee<br />

aged 18 or over can be required work in one week to 48. However, most workers can<br />

agree in writing to work longer than the 48-hour limit. The agreement must be signed<br />

by the worker.<br />

Working time includes travelling if part <strong>of</strong> the job, working lunches <strong>and</strong> job-related<br />

training. It does not include travelling between home <strong>and</strong> work, lunch breaks, evening<br />

classes or day-release courses.<br />

Workers can cancel the opt-out agreement whenever they want, although they must<br />

give their employer at least seven days' notice.<br />

The regulations also require employees to take rest breaks during the working day. It<br />

is important that breaks are taken to ensure that employees can maintain<br />

concentration <strong>and</strong> combat fatigue.<br />

Detailed guidance on interpretation <strong>of</strong> the Working Time Regulations is given in on<br />

the Business Link website at:http://www.businesslink.gov.uk/bdotg/action/layer?r.l1=1073858787&topicId=107385<br />

8926&r.lc=en&r.s=tl<br />

39


14.0 Approaches to <strong>Thorough</strong> <strong>Examination</strong><br />

14.1 Introduction<br />

The primary purpose <strong>of</strong> thorough examination is to ensure that a mobile crane is safe<br />

to be taken into, or to continue in, use. It is in addition to any inspection carried out as<br />

a part <strong>of</strong> the maintenance regime <strong>and</strong> is a statutory requirement.<br />

<strong>Mobile</strong> cranes operate in a high risk environment in close proximity to people. These<br />

factors must be taken into account by the competent person when determining the<br />

scope <strong>and</strong> nature <strong>of</strong> the thorough examination.<br />

NOTE: The thorough examination is not part <strong>of</strong> the maintenance regime for the equipment but<br />

provides owners with information which could be used to determine the effectiveness <strong>of</strong> the<br />

regime. The competent person may require supplementary tests as part <strong>of</strong> thorough<br />

examination. See BS 7121-2 <strong>and</strong> BS 7121-3.<br />

NOTE: The legal requirements covering thorough examination are set out in HSE publication<br />

L113 - Approved Code <strong>of</strong> Practice <strong>and</strong> Guidance to LOLER. It is essential that anyone<br />

undertaking thorough examinations <strong>of</strong> mobile cranes or the management <strong>of</strong> the thorough<br />

examination <strong>of</strong> mobile cranes obtains <strong>and</strong> familiarises themselves with this document.<br />

14.2 Types <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

There are three situations where thorough examination is required by Regulation 9 <strong>of</strong><br />

LOLER:-<br />

� Before being put into use for the first time, LOLER Regulation 9(1);<br />

� Periodically whilst in service, LOLER Regulation 9(3)(a)(i)&(ii);<br />

� After exceptional circumstances have occurred, LOLER Regulation<br />

9(3)(a)(iv).<br />

14.3 Initial <strong>Thorough</strong> <strong>Examination</strong><br />

Before being put into use for the first time a mobile crane must be thoroughly<br />

examined to ensure that it is safe to use. The only exception to this is if the crane is<br />

new <strong>and</strong> the owner has an EC Declaration <strong>of</strong> Conformity that was made not more<br />

than twelve months prior to the crane being used for the first time. In this case the<br />

Declaration <strong>of</strong> Conformity will cover the use <strong>of</strong> the crane for the first six or twelve<br />

month period.<br />

14.4 Periodic <strong>Thorough</strong> <strong>Examination</strong><br />

A mobile crane must be thoroughly examined periodically to ensure that it is safe to<br />

continue in use. LOLER specifies that the maximum statutory intervals between<br />

thorough examinations are six months for mobile cranes that lift people <strong>and</strong> twelve<br />

months for mobile cranes that lift goods only.<br />

14.5 <strong>Thorough</strong> <strong>Examination</strong> Interval<br />

The statutory maximum intervals <strong>of</strong> six <strong>and</strong> twelve months may be reduced, taking<br />

into account environmental factors or the general age <strong>and</strong> condition <strong>of</strong> the crane etc.<br />

The decision to reduce the interval between thorough examinations may be made by<br />

the competent person, mobile crane owner or mobile crane user.<br />

Reasons for reduction <strong>of</strong> the interval between thorough examinations include:-<br />

� <strong>Mobile</strong> cranes frequently work above or near people, both personnel on site<br />

<strong>and</strong> members <strong>of</strong> the public outside the site;<br />

40


� <strong>Mobile</strong> cranes will be used for lifting <strong>of</strong> persons in exceptional<br />

circumstances, including rescue, even if it is not initially planned;<br />

� The intensity <strong>of</strong> use <strong>and</strong> the environment in which they are used;<br />

� Following review by the competent person <strong>of</strong> the in-service lift plan (risk<br />

assessment, method statement <strong>and</strong> schedule <strong>of</strong> lifts) to ascertain the likely<br />

load spectrum <strong>and</strong> frequency <strong>of</strong> use <strong>of</strong> the crane.<br />

14.6 <strong>Thorough</strong> <strong>Examination</strong> After Exceptional Circumstances<br />

If the mobile crane is subjected to exceptional circumstances it should be removed<br />

from service <strong>and</strong> subjected to a thorough examination to ensure that it is safe to be<br />

returned to service. Exceptional circumstances may include an overload, jib clash,<br />

use for particularly arduous duties, failure <strong>of</strong> a structural component or being<br />

subjected to weather in excess <strong>of</strong> design parameters.<br />

14.7 <strong>Examination</strong> Schemes<br />

As an alternative to the maximum intervals <strong>of</strong> twelve <strong>and</strong> six months for periodic<br />

thorough examination LOLER allows a competent person to draw up an “examination<br />

scheme” for an item <strong>of</strong> lifting equipment such as a mobile crane. This scheme must<br />

take account <strong>of</strong> the condition <strong>of</strong> the equipment, maintenance <strong>and</strong> previous thorough<br />

examination history, the environment in which it is to be used, the number <strong>of</strong> lifting<br />

operations to be carried out <strong>and</strong> the magnitude <strong>of</strong> the loads to be lifted. As a result <strong>of</strong><br />

this detailed analysis <strong>of</strong> the equipment’s condition <strong>and</strong> use the competent person will<br />

specify the intervals at which periodic thorough examinations must be carried out.<br />

These intervals may be shorter or longer than the six or twelve month intervals <strong>and</strong><br />

will reflect the anticipated rate <strong>of</strong> deterioration <strong>and</strong> likelihood <strong>and</strong> consequences <strong>of</strong><br />

failure.<br />

<strong>Examination</strong> schemes are a useful approach where lifting equipment is used in well<br />

defined circumstances <strong>and</strong> a consistent environment, such as a manufacturing plant.<br />

Lifting equipment such as mobile cranes used in the construction industry are<br />

however, used in ever changing circumstances with arduous duties <strong>and</strong> lifting over<br />

people. In addition examination schemes require significant time to draw up, validate<br />

<strong>and</strong> administer.<br />

Best Practice guidance suggests that the examination scheme approach is totally<br />

unsuitable <strong>and</strong> periodic thorough examinations using a defined scope should be used<br />

for all mobile cranes.<br />

14.8 Defined Scope for Periodic <strong>Thorough</strong> <strong>Examination</strong><br />

<strong>Mobile</strong> cranes are sophisticated <strong>and</strong> complex machines <strong>and</strong> as such, the competent<br />

person carrying out a thorough examination should work to a defined scope <strong>of</strong><br />

examination for each mobile crane they are required to examine.<br />

The defined scope <strong>of</strong> examination should be drawn up in advance <strong>of</strong> the examination<br />

by a competent person <strong>and</strong> identify those parts <strong>of</strong> the mobile crane that should be<br />

thoroughly examined, together with required supplementary supporting reports <strong>and</strong><br />

tests. The defined written scope <strong>of</strong> examination should specify the intervals at which<br />

the mobile crane (or individual parts there<strong>of</strong>) should be thoroughly examined (within<br />

the statutory maximum periods specified by LOLER <strong>of</strong> 6 <strong>and</strong> 12 months) <strong>and</strong>, where<br />

appropriate, intervals for specific reports <strong>and</strong> tests. A non-exhaustive list <strong>of</strong><br />

supplementary supporting reports <strong>and</strong> tests is provided in Annex 10<br />

The competent person who draws up the scope <strong>of</strong> examination should be formally<br />

appointed. The competent person may be employed by the user, owner,<br />

41


manufacturer or some other independent party provided they have the necessary<br />

competence. The person could also carry out the thorough examinations,<br />

supplementary reports <strong>and</strong> tests <strong>of</strong> the mobile crane. However in practice it is likely<br />

that these will be undertaken by other competent persons who are suitably<br />

knowledgeable <strong>and</strong> trained. The defined written scope <strong>of</strong> examination should detail<br />

whom, or which organisation, should undertake thorough examinations including any<br />

supporting supplementary reports <strong>and</strong> tests <strong>and</strong> the extent to which they should be<br />

witnessed.<br />

The defined written scope <strong>of</strong> examination must take account <strong>of</strong> manufacturer’s<br />

information (which may include a scope <strong>of</strong> examination), maintenance history,<br />

previous thorough examination history, the environment in which it is to be used, the<br />

number <strong>of</strong> lifting operations to be carried out <strong>and</strong> the magnitude <strong>of</strong> the loads to be<br />

lifted. As a result <strong>of</strong> this detailed analysis <strong>of</strong> the mobile crane’s history <strong>and</strong> use, the<br />

competent person will specify the intervals at which periodic thorough examinations,<br />

supporting supplementary reports <strong>and</strong> tests must be carried out. These intervals<br />

should reflect the anticipated rate <strong>of</strong> deterioration <strong>and</strong> likelihood <strong>and</strong> consequences<br />

<strong>of</strong> failure.<br />

It is likely that generic scopes <strong>of</strong> examination, supported by crane specific<br />

information, can be written for specific makes <strong>and</strong> models <strong>of</strong> mobile crane. This may<br />

need to be supplemented by the competent person carrying out the thorough<br />

examination in the light <strong>of</strong> the findings <strong>of</strong> the thorough examination.<br />

The defined written scope <strong>of</strong> examination should be capable <strong>of</strong> being reproduced as<br />

a written copy when required; it should be secure from loss or unauthorised<br />

modification <strong>and</strong> it should be authenticated by the competent person preparing the<br />

written scope. The competent person should periodically review the defined written<br />

scope <strong>of</strong> examination to take account <strong>of</strong> changes in usage <strong>of</strong> the equipment, findings<br />

<strong>of</strong> previous thorough examinations, supporting supplementary reports <strong>and</strong> tests<br />

together with any information from maintenance activities, manufacturers or other<br />

sources.<br />

Best Practice guidance suggests that a defined written scope <strong>of</strong> examination<br />

approach should be used for all mobile cranes with thorough examinations<br />

undertaken at defined intervals within the statutory maximum periods. Supporting<br />

supplementary reports <strong>and</strong> tests may be undertaken at longer intervals at the<br />

discretion <strong>of</strong> the competent person.<br />

An example <strong>of</strong> a typical defined written scope <strong>of</strong> examination is shown in Annex 3.<br />

14.9 Four year test<br />

In the past mobile cranes in the UK have frequently been subjected to overload<br />

testing at four yearly intervals, in addition to the periodic thorough examinations<br />

required by LOLER. This is a legacy from the requirements <strong>of</strong> the old Construction<br />

(Lifting Operations) Regulations, which were replaced by the introduction <strong>of</strong> LOLER<br />

in 1998. The Approved Code <strong>of</strong> Practice to LOLER states that any testing is at the<br />

discretion <strong>of</strong> the competent person carrying out a thorough examination <strong>and</strong> that the<br />

competent person will decide on the nature <strong>of</strong> the test <strong>and</strong> the method <strong>of</strong> carrying it<br />

out.<br />

The traditional routine overload testing <strong>of</strong> mobile cranes has a number <strong>of</strong><br />

disadvantages <strong>and</strong> few benefits:-<br />

� Some manufacturers do not recommend overload tests, except in “exceptional”<br />

circumstances <strong>and</strong> severely limit the magnitude <strong>of</strong> the test load that may be<br />

applied;<br />

42


� Repeated overloads may have a deteriorating effect on the crane structure over<br />

time;<br />

� Most structural failures are the result <strong>of</strong> fatigue <strong>and</strong> such defects will not be<br />

highlighted by an overload test;<br />

� Fatigue cracking should be identified during thorough examination;<br />

� If a crane fails during testing it could be dangerous <strong>and</strong> will certainly be<br />

expensive;<br />

� <strong>Inspection</strong> bodies such as the engineering insurers do not recommend it, as<br />

there is no defined structural or mechanical benefit;<br />

� A significant number <strong>of</strong> insurance policies do not provide cover for a crane that<br />

has been overloaded in any circumstances including overload testing.<br />

In summary, where a defined written scope <strong>of</strong> examination approach is used four<br />

yearly overload testing is not required unless deemed necessary by the competent<br />

person.<br />

14.10 <strong>Mobile</strong> Crane Users Responsibilities for <strong>Thorough</strong> <strong>Examination</strong><br />

Regulation 9 <strong>of</strong> the Lifting Operations <strong>and</strong> Lifting Equipment Regulations 1998<br />

(LOLER) requires employers to ensure that mobile cranes have a current report <strong>of</strong><br />

thorough examination before the crane is used. (See 14.2). In the case <strong>of</strong> a hired-in<br />

mobile crane the actual undertaking <strong>of</strong> thorough examinations is <strong>of</strong>ten delegated to<br />

the crane owner by the user. The user however, retains the legal responsibility for<br />

ensuring that thorough examinations are carried out.<br />

43


15.0 Management <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

15.1 Introduction<br />

LOLER permits thorough examination to be carried out by competent persons from<br />

third party in-service inspection organizations or by “in-house” examiners. All<br />

competent persons are required to have “such appropriate practical <strong>and</strong> theoretical<br />

knowledge <strong>and</strong> experience <strong>of</strong> the lifting equipment to be thoroughly examined as will<br />

enable them to detect defects or weaknesses <strong>and</strong> to assess their importance in<br />

relation to the safety <strong>and</strong> continued use <strong>of</strong> the lifting equipment.” It is also “essential<br />

that the competent person is sufficiently independent <strong>and</strong> impartial to allow objective<br />

decisions to be made.”<br />

15.2 Use <strong>of</strong> a Third Party <strong>Inspection</strong> Body<br />

Many third party inspection bodies who carry out thorough examinations <strong>of</strong> mobile<br />

cranes, such as full members <strong>of</strong> the Safety Assessment Federation, will hold<br />

accreditation to ISO 17020.<br />

In order to satisfy such accreditation requirements the following must be included:-<br />

� Verification <strong>of</strong> an organisation’s independence for the function <strong>of</strong> inspection<br />

(thorough examination). (There should be no conflict <strong>of</strong> interest between the<br />

inspection function <strong>and</strong> activities such as potential sales <strong>of</strong> cranes, design,<br />

supply <strong>of</strong> parts, maintenance or repair See 15.4);<br />

� Identification <strong>and</strong> stipulation <strong>of</strong> the limiting scope <strong>of</strong> activity for the<br />

organisation (i.e. defining the inspection competencies <strong>of</strong> the organisation);<br />

� Sufficiently documented processes <strong>and</strong> procedures (Procedural, Quality <strong>and</strong><br />

Health & Safety) supporting the thorough examinations undertaken;<br />

� Evidence that documentation has been periodically reviewed <strong>and</strong> relevant<br />

information provided to the competent person (e.g. defined scope <strong>of</strong><br />

examination, processes <strong>and</strong> procedures);<br />

� The auditing <strong>of</strong> these processes <strong>and</strong> procedures on a periodic basis, by a<br />

recognised accreditation body;<br />

� The performance assessment, by the accreditation body, <strong>of</strong> the organisation’s<br />

in-house audit schedule <strong>and</strong> that non-conformity action has been suitably<br />

completed;<br />

� The auditing, by the accreditation body, <strong>of</strong> the competent person’s training<br />

records;<br />

� The auditing, by the accreditation body, <strong>of</strong> the thorough examinations carried<br />

out by competent persons;<br />

� The auditing, by the accreditation body, <strong>of</strong> the reporting process to ensure<br />

that enforcing authority reports are issued as appropriate without fear or<br />

favour <strong>and</strong> within required timescales. This will also include report format<br />

compliance with legislative requirements.<br />

� Adequate time is allowed for each examination<br />

The benefit <strong>of</strong> a third party inspection body is that the competent person will, by<br />

definition, be independent from all aspects <strong>of</strong> the maintenance <strong>and</strong> operational<br />

management <strong>of</strong> the mobile crane. They may, however, not have the detailed product<br />

knowledge that an in-house competent person might possess but they will have been<br />

comprehensively trained <strong>and</strong> assessed in thorough examination techniques <strong>and</strong> will<br />

know when to ask for product specific information. They will look at a crane from a<br />

44


different perspective than someone regularly involved in the maintenance <strong>of</strong> that type<br />

or model <strong>of</strong> crane.<br />

Third party inspection bodies should be selected with care, as not all bodies will have<br />

the required level <strong>of</strong> generic <strong>and</strong> specific product knowledge required for the effective<br />

thorough examination <strong>of</strong> mobile cranes.<br />

Use <strong>of</strong> a third party body will require management input from the crane owner <strong>and</strong><br />

user in terms <strong>of</strong> making the mobile crane available, providing details <strong>of</strong> crane<br />

configuration, maintenance carried out, preparation <strong>of</strong> the crane for thorough<br />

examination, supplementary tests <strong>and</strong> management <strong>of</strong> thorough examination reports.<br />

Both parties must also be prepared to take a crane out <strong>of</strong> service if the third party<br />

competent person carrying out a thorough examination identifies defects which<br />

immediately affect the safety <strong>of</strong> persons.<br />

It is essential that the mobile crane owner <strong>and</strong> the competent person, or his<br />

employer, agree <strong>and</strong> periodically review, the programme <strong>and</strong> information<br />

requirements for thorough examinations, including the specific supplementary test<br />

reports that will be provided prior to each thorough examination. This is especially<br />

important when a new external provider has been appointed.<br />

NOTE: The United Kingdom Accreditation Service (UKAS) is the sole UK body authorised by<br />

The Department for Business, Innovation <strong>and</strong> Skills (BIS) to carry out accreditation to ISO<br />

17020.<br />

15.3 Carrying Out <strong>Thorough</strong> <strong>Examination</strong> In-house<br />

As noted above, LOLER permits the use <strong>of</strong> in-house competent persons. Their<br />

employer must, however, ensure that they “have the genuine authority <strong>and</strong><br />

independence to ensure that examinations are properly carried out <strong>and</strong> that the<br />

necessary recommendations arising from them are made without fear or favour.” This<br />

can only be demonstrated by means <strong>of</strong> a clearly defined autonomous management<br />

structure with built in checks <strong>and</strong> balances to ensure that the necessary degree <strong>of</strong><br />

independence is achieved. One means <strong>of</strong> demonstrating this is accreditation to ISO<br />

17020.<br />

15.4 In-house <strong>Thorough</strong> <strong>Examination</strong> Management Structure<br />

If thorough examination <strong>of</strong> mobile cranes is being undertaken in-house an effective<br />

management structure should be put in place to ensure that everyone involved in the<br />

activity is aware <strong>of</strong> their responsibilities, properly briefed on their duties <strong>and</strong> that systems<br />

are in place to demonstrate independence <strong>and</strong> enable effective feedback including the<br />

monitoring <strong>of</strong> thorough examination. A sample structure is shown in Fig. 3.<br />

A number <strong>of</strong> measures can be taken which will help establish the independence <strong>of</strong><br />

the competent persons:-<br />

� A fully documented, detailed <strong>and</strong> independently audited quality system such<br />

as ISO 9001;<br />

� The thorough examination function reporting straight to the Managing<br />

Director or equivalent;<br />

� An undertaking that the competent person will never examine their own<br />

maintenance work, be involved in the operational management <strong>of</strong> the mobile<br />

crane or be involved in any other conflicting activities;<br />

� A statement that in the case <strong>of</strong> any conflict, the Managing Director will<br />

always back the competent person against commercial pressures from other<br />

parts <strong>of</strong> the organisation;<br />

45


� The competent person has the authority to stop the operation <strong>of</strong> any mobile<br />

crane owned or operated by the company;<br />

� The competent person has the authority to send reports <strong>of</strong> examination<br />

where there is an imminent danger <strong>of</strong> serious personal injury to the<br />

enforcing authority (HSE or Local Authority);<br />

� The pay <strong>and</strong> rewards <strong>of</strong> competent persons should not depend on the<br />

number <strong>of</strong> thorough examinations completed in a given period or the<br />

findings <strong>of</strong> those examinations.<br />

From this it is also clear that in-service thorough examinations, where a member <strong>of</strong><br />

the maintenance team examines his own work would not have the required degree <strong>of</strong><br />

independence. Members <strong>of</strong> the maintenance team may undertake supplementary<br />

inspections, tests <strong>and</strong> reports requested by the competent person.<br />

15.5 Auditing <strong>of</strong> In-house <strong>Thorough</strong> <strong>Examination</strong> Management Systems<br />

Once an in-house thorough examination system has been established it is important<br />

that it is regularly audited to ensure that the system is being adhered to <strong>and</strong> that it is<br />

functioning correctly. Auditing should be carried out by an auditor from outside the<br />

thorough examination department with a sufficient degree <strong>of</strong> independence.<br />

If a business has a formal quality management system such as an ISO 9001<br />

accredited system the thorough examination activity should be integrated into that<br />

system <strong>and</strong> the scheduled audits.<br />

Strong consideration should also be given to obtaining UKAS accreditation to ISO<br />

17020 as an in-service inspection body.<br />

Health, Safety <strong>and</strong><br />

Environment<br />

Function<br />

<strong>Thorough</strong><br />

<strong>Examination</strong> Function<br />

Manager<br />

Competent<br />

Persons (<strong>Thorough</strong><br />

<strong>Examination</strong>)<br />

Managing Director<br />

Admin <strong>and</strong><br />

Records<br />

Figure 3. – Typical In-house <strong>Thorough</strong> <strong>Examination</strong> Organisation<br />

Structure<br />

46<br />

<strong>Maintenance</strong><br />

Manager<br />

Internal Quality <strong>and</strong><br />

Audit Function<br />

External Audit<br />

Function<br />

Senior Manager<br />

Hire<br />

Manager


16.0 Competent Persons – Attributes, Training <strong>and</strong> Assessment<br />

16.1 Introduction<br />

It is essential that the thorough examination <strong>of</strong> mobile cranes is always carried out by<br />

competent persons who have been assessed as competent <strong>and</strong> have adequate<br />

training, information <strong>and</strong> independence to carry out the work required.<br />

16.2 Attributes<br />

Competent persons carrying out the thorough examination <strong>of</strong> mobile cranes should<br />

have the following attributes:<br />

Personal Attributes<br />

� Be physically fit;<br />

� Be comfortable working at height;<br />

� Have a responsible attitude;<br />

� Be able to communicate clearly with other personnel on site;<br />

� Be familiar with working on construction sites <strong>and</strong> site specific safety<br />

requirements;<br />

� Be aware <strong>of</strong> their responsibilities under the Health <strong>and</strong> Safety at Work Act<br />

<strong>and</strong> supporting regulations;<br />

� Be trained in the use, pre-use checks <strong>and</strong> maintenance <strong>of</strong> their personal<br />

protective equipment <strong>and</strong> capable <strong>of</strong> using it correctly.<br />

Knowledge Base<br />

� Have an underst<strong>and</strong>ing <strong>of</strong> the legislative requirements for thorough<br />

examination;<br />

� Have an underst<strong>and</strong>ing <strong>of</strong> the mobile crane design St<strong>and</strong>ards <strong>and</strong> codes <strong>of</strong><br />

practice for the selection <strong>and</strong> use <strong>of</strong> mobile cranes, together with the<br />

applicable inspection/examination criteria;<br />

� Have an underst<strong>and</strong>ing <strong>of</strong> the safety rules <strong>and</strong> associated codes <strong>of</strong> practice<br />

that are applicable to mobile cranes;<br />

� Have an underst<strong>and</strong>ing <strong>of</strong> the inspection <strong>and</strong> maintenance requirements <strong>of</strong><br />

mobile cranes;<br />

� Have knowledge <strong>of</strong> appropriate test procedures which may be employed<br />

<strong>and</strong> the interpretation <strong>and</strong> limitations <strong>of</strong> those techniques;<br />

� Have an underst<strong>and</strong>ing <strong>of</strong> drawings <strong>and</strong> manufacturing literature relevant to<br />

the mobile cranes to be inspected or examined;<br />

� Have knowledge <strong>of</strong> the materials <strong>and</strong> techniques used in the manufacture<br />

<strong>and</strong> assembly <strong>of</strong> the mobile cranes;<br />

� Be aware <strong>of</strong> their own limitations.<br />

Practical Skills<br />

� Be capable <strong>of</strong> detecting defects or weaknesses in mobile cranes which<br />

could compromise the safety <strong>of</strong> the mobile crane;<br />

� Have sufficient knowledge <strong>and</strong> experience to assess the importance <strong>of</strong><br />

defects or weaknesses in the mobile crane <strong>and</strong> identifying what actions<br />

47


need to be taken in order to rectify them. In particular they should be able<br />

to:o<br />

verify that the mobile crane is operating as intended;<br />

o specify the appropriate time-scales within which identified defects or<br />

weaknesses need to be rectified;<br />

o establish that defects identified in the previous report <strong>of</strong> thorough<br />

examination have received attention;<br />

o assess the correct function <strong>of</strong> all safety devices;<br />

o check that warning notices are correctly fixed <strong>and</strong> legible; <strong>and</strong> where<br />

necessary specify any limitations on the use <strong>of</strong> the mobile crane;<br />

o witness any testing required as part <strong>of</strong> thorough examination;<br />

o report on the findings <strong>of</strong> the thorough examination.<br />

16.3 Qualifications <strong>and</strong> Experience<br />

Competent persons should have both appropriate recognised formal qualifications<br />

<strong>and</strong> a relevant level <strong>of</strong> practical experience in a related engineering field.<br />

The following are examples <strong>of</strong> those with the cumulative attributes necessary to<br />

support competence:<br />

� Engineering Technician as defined by the Engineering Council or equivalent<br />

(e.g. appropriate ONC with relevant experience) having a minimum <strong>of</strong> 5 years<br />

experience within a relevant discipline <strong>of</strong> which at least one year shall have<br />

been spent working within an engineering discipline related to lifting<br />

equipment;<br />

� Person trained in a relevant engineering discipline with a recognised <strong>and</strong><br />

documented engineering apprenticeship (in lieu <strong>of</strong> an academic qualification)<br />

with a minimum <strong>of</strong> 5 years experience within a relevant discipline <strong>of</strong> which at<br />

least one year shall have been spent working within an engineering discipline<br />

related to lifting equipment;<br />

� Level 4 (Engineer Surveyor National Vocational Qualifications (NVQ) are<br />

available for competent persons carrying out thorough examination <strong>of</strong> mobile<br />

cranes.<br />

Employers must determine competence <strong>of</strong> each individual person, both existing<br />

employees <strong>and</strong> new entrants, based on the attributes listed above together with<br />

formal qualifications. A shortfall on attainment level does not preclude employment in<br />

this role but such shortfalls must be addressed before the person is allowed to carry<br />

out unsupervised thorough examinations <strong>of</strong> mobile cranes.<br />

16.4 Competent Person Selection<br />

Competent persons should be selected through a formally documented assessment<br />

process.<br />

The purpose <strong>of</strong> the assessment, which must include a sufficiently robust technical<br />

interview <strong>and</strong> other elements, is to determine whether or not the interviewee has the<br />

general aptitude <strong>and</strong> appropriate level <strong>of</strong> relevant underpinning knowledge <strong>and</strong><br />

underst<strong>and</strong>ing to perform the intended duties <strong>of</strong> a competent person when combined<br />

with the training provided by the employer.<br />

16.5 Training Plan<br />

48


An individual training plan should be drawn up for each person who is to carry out the<br />

thorough examination <strong>of</strong> mobile cranes. Achievement <strong>of</strong> this plan <strong>and</strong> continuing<br />

pr<strong>of</strong>essional development should be monitored at frequent intervals as part <strong>of</strong> the<br />

management review process (See Section 19) <strong>and</strong> included in the quality system<br />

(e.g. ISO 9000) auditing process.<br />

16.6 Training Courses<br />

Training courses covering both the management <strong>and</strong> practice <strong>of</strong> thorough<br />

examinations are available from training organisations such as the National<br />

Construction College at:www.citb-constructionskills.co.uk/traininglearning/nationalconstructioncollege<br />

16.7 Technical Product Awareness<br />

Before carrying the thorough examination <strong>of</strong> a specific make <strong>and</strong> model <strong>of</strong> mobile<br />

crane all personnel should receive technical information from the crane manufacturer<br />

or the employer. This may be carried out in-house by a trainer who has received<br />

model specific technical training directly from the manufacturer.<br />

16.8 Assessment<br />

It is important that all competent persons are assessed on appointment, within 12<br />

months <strong>and</strong> at regular intervals (not exceeding four years) thereafter. Assessment<br />

should form part <strong>of</strong> any training.<br />

16.9 Continuing Pr<strong>of</strong>essional Development<br />

Continuing Pr<strong>of</strong>essional Development (CPD) is the conscious updating <strong>of</strong><br />

pr<strong>of</strong>essional knowledge <strong>and</strong> the improvement <strong>of</strong> a competent person’s competency<br />

throughout their working life. This is a joint responsibility between the competent<br />

person <strong>and</strong> their employer.<br />

The competent person’s employer should maintain a training, experience <strong>and</strong><br />

development record for each competent person. The record should include details <strong>of</strong><br />

how CPD is being achieved <strong>and</strong> should include for example:<br />

� Initial training towards achievement <strong>of</strong> competency;<br />

� Specific training towards enhancements/additions to competency;<br />

� Familiarisation/re-familiarisation, coaching <strong>and</strong> training;<br />

� Any alterations <strong>and</strong>/or withdrawals <strong>of</strong> competency;<br />

� Enhancements to qualifications;<br />

� Membership <strong>of</strong> pr<strong>of</strong>essional bodies/institutions;<br />

� Attendance at seminars <strong>and</strong> any refresher training courses;<br />

� Visits to manufacturers <strong>and</strong> trade shows.<br />

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16.10 Training Records<br />

A comprehensive individual training record should be established for all personnel<br />

carrying out thorough examinations. This should be updated as training is undertaken<br />

<strong>and</strong> as a minimum should include:<br />

� When the training took place;<br />

� Where the training took place;<br />

� The scope <strong>of</strong> the training including types <strong>and</strong> models <strong>of</strong> mobile<br />

crane;<br />

� The duration <strong>of</strong> the training;<br />

� The outcome <strong>of</strong> the training;<br />

� Who delivered the training;<br />

� When refresher training is required.<br />

50


17.0 Developing the Defined Scope <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

17.1 Introduction<br />

It is important that a defined scope <strong>of</strong> thorough examination is drawn up before a<br />

thorough examination is undertaken on a mobile crane. This should cover at least the<br />

following:-<br />

� What is to be looked at;<br />

� How <strong>of</strong>ten;<br />

� <strong>Examination</strong> methods to be employed;<br />

� Details <strong>of</strong> any supplementary reports <strong>and</strong> tests;<br />

� Anticipated duration.<br />

The defined scope <strong>of</strong> thorough examination for an individual crane will comprise<br />

<strong>of</strong> generic elements applicable to most cranes, supplemented by crane specific<br />

elements derived from consideration <strong>of</strong> information including:-<br />

� Crane specific details<br />

� <strong>Maintenance</strong> <strong>and</strong> repair data<br />

� Manufacturer’s information (alerts <strong>and</strong> technical bulletins)<br />

� In-service history<br />

� Proposed future use<br />

This process is shown in Figure 4. below.<br />

Generic<br />

Element<br />

+<br />

Manufacturer’s<br />

Information<br />

Historical<br />

<strong>Maintenance</strong><br />

<strong>and</strong> Repair<br />

History<br />

<strong>Thorough</strong><br />

<strong>Examination</strong><br />

History<br />

Crane<br />

Specification<br />

Future Use<br />

Figure 4 – Elements <strong>of</strong> a Defined Scope <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

51<br />

Crane<br />

Specific<br />

Elements<br />

=<br />

Defined<br />

Scope <strong>of</strong><br />

<strong>Thorough</strong><br />

<strong>Examination</strong>


17.2 Compiling the Defined Scope <strong>of</strong> <strong>Examination</strong><br />

The generic elements <strong>of</strong> the defined scope <strong>of</strong> examination should be drawn up by a<br />

competent person within the inspection body. This document should be authorised by<br />

the competent person <strong>and</strong> periodically reviewed for continued relevance.<br />

The supplementary elements for the specific crane to be examined should be defined<br />

in advance <strong>of</strong> the examination by a competent person within the inspection body.<br />

These elements should be verified for relevance to the crane being examined <strong>and</strong><br />

amended as necessary, by the competent person carrying out the thorough<br />

examination before starting the examination.<br />

17.3 Information<br />

The wide variation <strong>of</strong> designs <strong>and</strong> the increasing complexity <strong>of</strong> mobile crane<br />

technology make it essential that all competent persons carrying out thorough<br />

examination are supplied with adequate information to enable them to carry out their<br />

duties effectively <strong>and</strong> safely. Information comes in various forms <strong>and</strong> from several<br />

sources.<br />

17.3.1 Manufacturer’s Information<br />

Information supplied by the mobile crane manufacturer or another competent source<br />

will be the main source <strong>of</strong> instructions <strong>and</strong> specifications when carrying out thorough<br />

examination. The primary document will be the maintenance manual for the specific<br />

crane model (<strong>and</strong> in some cases serial number), supplemented by technical<br />

information bulletins.<br />

Care should be taken to ensure that the information is up to date <strong>and</strong> relevant to the<br />

crane on which the thorough examination is being carried out.<br />

Manufacturer’s manuals are not always complete <strong>and</strong> in the case where particular<br />

information is not covered, the crane owner or manufacturer must be contacted for<br />

information BEFORE the thorough examination is undertaken. Manuals may not<br />

always contain an appropriate maintenance regime for older cranes, in which case<br />

the specific advice <strong>of</strong> the manufacturer should be sought.<br />

When purchasing a second h<strong>and</strong> crane care should be taken to ensure that any<br />

manuals supplied with the crane are appropriate for the specific model <strong>of</strong> crane.<br />

Some mobile crane manuals <strong>and</strong> other information are available to download from<br />

the manufacturer’s web site.<br />

17.3.2 In-House Technical Information<br />

Some mobile crane owners will have their own technical information dealing with<br />

specific issues relating to the cranes in their fleet. This can be a useful source <strong>of</strong><br />

information for thorough examination personnel but care should be taken to ensure<br />

that circulation is controlled to ensure that information is current <strong>and</strong> that outdated<br />

data has been withdrawn.<br />

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17.3.3 Generic Information<br />

Competent persons may also need to refer to generic information such as st<strong>and</strong>ards<br />

<strong>and</strong> industry guidance. Examples <strong>of</strong> these are BS ISO 4309:2004, <strong>Cranes</strong>. Wire<br />

ropes. Care, maintenance, installation, examination <strong>and</strong> discard, <strong>and</strong> wire rope<br />

manufacturer’s guidance.<br />

Care should be taken to ensure that the information is up to date.<br />

17.3.4 Machine History<br />

The history <strong>of</strong> the repairs <strong>and</strong> maintenance carried out on a mobile crane is essential<br />

to a competent person carrying out a thorough examination. Details <strong>of</strong> any structural<br />

repairs, welding <strong>and</strong> any non-routine maintenance must be presented to the<br />

competent person at the time <strong>of</strong> the next thorough examination.<br />

17.3.5 Supplementary Reports <strong>and</strong> Tests<br />

The purpose <strong>of</strong> the supplementary tests is to support the thorough examination in<br />

order to establish the equipment’s suitability for continued safe use. These<br />

supplementary tests may be specified by the competent person <strong>and</strong> can cover a wide<br />

range <strong>of</strong> techniques, not just overload testing. They will need to be undertaken,<br />

completed by the date specified <strong>and</strong> documented, in order to enable the subsequent<br />

thorough examination to be completed. Failure to complete the supplementary tests<br />

may preclude the completion <strong>of</strong> the subsequent thorough examination. In some<br />

circumstances the competent person may wish to witness the ‘supplementary tests’.<br />

The results <strong>of</strong> any tests not witnessed by the competent person should be forwarded<br />

to the competent person, for review, without delay<br />

Supplementary tests <strong>and</strong> corresponding reports on mobile cranes may include:-<br />

� Load test following major repair;<br />

� RCI/RCL calibration <strong>and</strong> functional test;<br />

� Anemometer calibration <strong>and</strong> functional test;<br />

� Non Destructive <strong>Examination</strong> <strong>of</strong> individual components;<br />

� Slew ring condition <strong>and</strong> clearances;<br />

� <strong>Maintenance</strong> records.<br />

Additional information on supplementary tests is given in Annex 10.<br />

In practice the mobile crane owner <strong>and</strong> the competent person may wish to agree <strong>and</strong><br />

periodically review the specific supplementary test reports that will be provided prior<br />

to each thorough examination. These should at least include functional test <strong>and</strong><br />

confirmation <strong>of</strong> calibration <strong>of</strong> RCI/RCL <strong>and</strong> hoist brake test. Additional supplementary<br />

tests will be requested by the competent person as circumstances dem<strong>and</strong>.<br />

17.3.6 Previous Reports <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong> <strong>and</strong> Supplementary Tests<br />

Where a mobile crane has been previously examined, the reports <strong>of</strong> the most recent<br />

thorough examination <strong>and</strong> any supplementary tests carried out should be made<br />

available to the competent person before they carry out the current thorough<br />

examination. Best practice guidance is that all reports <strong>of</strong> thorough examination are<br />

kept for the life <strong>of</strong> the mobile crane.<br />

17.3.7 Information on Clearance <strong>of</strong> Defects<br />

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Where a previous thorough examination report has identified defects requiring<br />

rectification, evidence <strong>of</strong> clearance <strong>of</strong> those defects should be made available to the<br />

competent person before they carry out the current thorough examination.<br />

17.3.8 Information Formats<br />

Paper information, such as that found in manuals <strong>and</strong> bulletins, is rapidly being<br />

replaced by electronic formats such as CD-ROM <strong>and</strong> website downloads. This has<br />

the advantage that physical storage space is kept to a minimum <strong>and</strong> information<br />

should be up to date at the point <strong>of</strong> access. However the use <strong>of</strong> electronic devices<br />

during thorough examination is not always easy or practical. Information may<br />

therefore have to be printed out for use on site, in which case care should be taken<br />

that for any subsequent use the data is current <strong>and</strong> relevant.<br />

Facilities should be available on site to print any document required by the competent<br />

person. Any print out should be marked “uncontrolled”.<br />

17.3.9 Management <strong>of</strong> Information<br />

Information should be managed effectively if it is to be <strong>of</strong> maximum benefit to those<br />

involved in the thorough examination process. Outdated information can at best<br />

waste time <strong>and</strong> at worst may well affect safety. It is therefore essential that<br />

organisations carrying out thorough examination <strong>of</strong> mobile cranes ensure that they<br />

have robust systems <strong>and</strong> procedures to ensure that personnel are supplied with<br />

adequate information that is both up to date <strong>and</strong> accurate. The crane manufacturer<br />

should be consulted to ensure that information is current.<br />

54


18.0 Reports <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

18.1 Introduction<br />

LOLER requires that the competent person carrying out a thorough examination <strong>of</strong> a<br />

mobile crane makes a report <strong>of</strong> that thorough examination in writing to the user <strong>of</strong> the<br />

crane <strong>and</strong> to the person from whom the crane has been hired. The report must be<br />

authenticated by the competent person, or on his behalf, <strong>and</strong> must contain the<br />

information specified in Schedule 1 to LOLER.<br />

18.2 Categorisation <strong>of</strong> Defects<br />

Where defects are found during the thorough examination <strong>of</strong> a mobile crane the<br />

competent person will make a judgement on the severity <strong>of</strong> the defect <strong>and</strong> its<br />

potential to affect the safety <strong>of</strong> persons. To assist this process defects are divided<br />

into three categories:-<br />

� Defects affecting the safety <strong>of</strong> persons that are to be remedied immediately;<br />

� Defects affecting the safety <strong>of</strong> persons that are to be remedied within a<br />

specified period <strong>of</strong> time;<br />

� Observations/recommendations which may require planning for resolution<br />

<strong>and</strong> may be outside the strict scope <strong>of</strong> the thorough examination.<br />

18.3 Required Level <strong>of</strong> Detail<br />

Defects should be reported in a sufficient level <strong>of</strong> detail to enable the crane owner to<br />

identify the exact location <strong>and</strong> nature <strong>of</strong> the defects, <strong>and</strong> decide on a course <strong>of</strong><br />

appropriate action to rectify those defects. Reports should be clear <strong>and</strong> readily<br />

understood by crane users. The use <strong>of</strong> abbreviations should be avoided.<br />

18.4 Distribution <strong>of</strong> Reports<br />

Generally mobile crane thorough examinations are carried out on behalf <strong>of</strong>, or by, the<br />

mobile crane owner. The thorough examination report is therefore sent to the crane<br />

owner who should then immediately send a copy to the mobile crane user as the<br />

user has a duty to ensure that the crane is safe to use.<br />

18.5 Report Completion Timescale<br />

Where defects are found during a thorough examination which are or could become<br />

a danger to persons then the competent person must inform both the user <strong>and</strong> the<br />

owner, so that the crane can either be prevented from being put into service or is<br />

taken out <strong>of</strong> service until the defects have been satisfactorily rectified. This is <strong>of</strong>ten<br />

accomplished by leaving an interim, h<strong>and</strong> written, report on site <strong>and</strong> making contact<br />

with the crane owner. In the case <strong>of</strong> an in-house competent person they will <strong>of</strong>ten<br />

have the authority to take the crane out <strong>of</strong> service immediately.<br />

Where the competent person identifies defects which need to be made good within a<br />

specified time scale <strong>and</strong> could become a danger to persons, they should submit the<br />

report promptly to allow the mobile crane owner to take the necessary action within<br />

the required period.<br />

In normal circumstances, the competent person should complete the report <strong>of</strong><br />

thorough examination <strong>and</strong> forward it within a maximum <strong>of</strong> 28 days.<br />

55


18.6 Inclusion <strong>of</strong> Cleared Defects<br />

On occasions the competent person carrying out the thorough examination will be<br />

accompanied by the mobile crane owner’s maintenance personnel <strong>and</strong> as defects<br />

are discovered they may be immediately rectified. In this case all defects MUST be<br />

reported even if they have been cleared. Failure to report defects is contrary to the<br />

requirements <strong>of</strong> LOLER, will give a false picture <strong>of</strong> the condition <strong>of</strong> the crane <strong>and</strong><br />

invalidate both the machine history <strong>and</strong> the review process.<br />

18.7 Notification to the Enforcing Authority<br />

Where, in the opinion <strong>of</strong> the competent person, the thorough examination identifies a<br />

serious defect in the mobile crane which involves an existing or imminent risk <strong>of</strong><br />

serious personal injury arising from failure <strong>of</strong> the crane which may occur at the next<br />

use or a short time thereafter, the competent person must send a copy <strong>of</strong> the report<br />

to the local <strong>of</strong>fice <strong>of</strong> the relevant enforcing authority. In most cases this will be the<br />

local <strong>of</strong>fice <strong>of</strong> the Health <strong>and</strong> Safety Executive.<br />

56


19.0 Management Review <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong> Records<br />

19.1 Introduction<br />

A regular management review <strong>of</strong> mobile crane thorough examination records is<br />

essential for the safe <strong>and</strong> efficient operation <strong>of</strong> a mobile crane fleet. It ensures that<br />

management can be confident that robust maintenance <strong>and</strong> thorough examination<br />

systems are in place <strong>and</strong> will rapidly highlight any shortcomings <strong>and</strong> the need for<br />

corrective action. It may be beneficial to include competent persons or the employer<br />

<strong>of</strong> third party competent persons in this process.<br />

19.2 Benefits<br />

The benefits <strong>of</strong> regular management review <strong>of</strong> thorough examination records are:-<br />

� Confidence that the system is functioning correctly;<br />

� Identification <strong>of</strong> extraordinary defects, events <strong>and</strong> failures;<br />

� Ensuring that there is evidence <strong>of</strong> adequate maintenance <strong>and</strong> thorough<br />

examination to the Enforcing Authorities in the event <strong>of</strong> an incident <strong>and</strong> a<br />

subsequent investigation;<br />

� Establishing trends over time <strong>and</strong> informing the review <strong>of</strong> the examination<br />

frequency;<br />

� Feedback to the maintenance activity;<br />

� Identification <strong>of</strong> component failure trends for feedback to the manufacturer;<br />

� Highlighting on-site thorough examination access problems for feedback to<br />

the manufacturer to improve future designs;<br />

� Monitoring the performance <strong>of</strong> individual cranes over time to provide<br />

information on future purchases;<br />

� Ensuring that defects are rectified in a timely manner.<br />

19.3 Review Frequency<br />

The review should be carried out initially at least monthly. Once a suitable level <strong>of</strong><br />

confidence in the systems has been established the review frequency may be<br />

reduced in the light <strong>of</strong> experience.<br />

19.4 Review Methodology<br />

The review should aim to identify exceptional events such as occurrences <strong>of</strong> heavy<br />

expenditure <strong>and</strong> reoccurring faults. It should also measure achievement <strong>of</strong><br />

maintenance activities against target. An example <strong>of</strong> the use <strong>of</strong> such Key<br />

Performance Indicators is given in Annex 10.<br />

19.5 Review Records<br />

It is essential that written records <strong>of</strong> the management review are made, both as<br />

evidence that the reviews have been undertaken <strong>and</strong> to evaluate long term trends.<br />

57


20.0 Practical Issues for <strong>Thorough</strong> <strong>Examination</strong> in a Depot<br />

20.1 Introduction<br />

When a through examination <strong>of</strong> a mobile crane is to be carried out in the owner’s<br />

depot or other <strong>of</strong>f site premises it is essential that there is effective liaison between<br />

the competent person carrying out the thorough examination <strong>and</strong> the person in<br />

charge <strong>of</strong> the premises. Before starting the thorough examination both parties must<br />

recognise each others requirements <strong>and</strong> agree the method by which these<br />

requirements will be met.<br />

The person in charge <strong>of</strong> the premises must make the competent person aware <strong>of</strong> any<br />

site specific hazards <strong>and</strong> arrange for the provision <strong>of</strong> the facilities required by the<br />

competent person.<br />

20.2 Lines <strong>of</strong> Communication<br />

Those planning <strong>and</strong> carrying out the thorough examination <strong>of</strong> mobile cranes on site<br />

must ensure that they have effective lines <strong>of</strong> communication with the site for initial,<br />

periodic <strong>and</strong> exceptional thorough examinations including preparation. This will avoid<br />

much frustration <strong>and</strong> misunderst<strong>and</strong>ing on both sides.<br />

20.3 Availability <strong>of</strong> Operators<br />

<strong>Thorough</strong> examination will require the crane to be operated from the control cab<br />

whilst the competent person is examining other parts <strong>of</strong> the crane. Arrangements<br />

must be made to ensure that an operator is available on such occasions.<br />

20.4 Availability <strong>of</strong> <strong>Maintenance</strong> Staff<br />

If the competent person carrying out the thorough examination requires the removal<br />

<strong>of</strong> covers <strong>and</strong> guards to facilitate the through examination <strong>of</strong> concealed parts, the<br />

owner <strong>of</strong> the crane should ensure that suitable personnel are available.<br />

20.5 <strong>Thorough</strong> <strong>Examination</strong> Area<br />

The area in which the thorough examination is being carried out should be <strong>of</strong><br />

adequate size <strong>and</strong> cordoned <strong>of</strong>f to prevent access by persons not directly involved in<br />

the examination.<br />

20.6 Test Area<br />

Careful consideration should be given to the condition <strong>of</strong> any area where tests are to<br />

be conducted. The recommendations provided in the operating instructions for the<br />

crane relate to operations within the rated capacity <strong>and</strong> more stringent requirements<br />

apply when loads are being applied for the purpose <strong>of</strong> testing.<br />

The ground should be level, well consolidated <strong>and</strong> capable <strong>of</strong> withst<strong>and</strong>ing the loads<br />

applied to it. There should be no hidden dangers such as cable ducts, drains, pipes,<br />

back-filled areas, cellars or other subterranean weaknesses. <strong>Cranes</strong> should not be<br />

tested in the vicinity <strong>of</strong> overhead power lines.<br />

The test site should be <strong>of</strong> sufficient size with unrestricted overhead clearance to allow<br />

the unobstructed movement <strong>of</strong> the crane <strong>and</strong> load throughout its test movement, for<br />

example slewing, derricking <strong>and</strong> travelling.<br />

It is preferable that tests are not conducted over high risk areas, for example a public<br />

highway, railway, occupied buildings, or in the flight path <strong>of</strong> airports. If due to the<br />

58


equirements <strong>of</strong> usage this is unavoidable, arrangements should be made with the<br />

appropriate authorities.<br />

If load testing is being carried it must be borne in mind that the crane might not<br />

withst<strong>and</strong> the loading. All personnel not essential to the test should be kept away<br />

from the area. The test area should be cordoned <strong>of</strong>f <strong>and</strong> notices posted prohibiting<br />

unauthorized entry. The site adjacent to the test area should be clear <strong>of</strong> plant <strong>and</strong><br />

property which could inhibit the test.<br />

20.7 Availability <strong>of</strong> Facilities<br />

Arrangements should be made to ensure that management, safety <strong>and</strong> welfare<br />

facilities are available to the competent person <strong>and</strong> any personnel assisting them<br />

both within <strong>and</strong> outside normal working hours. Facilities should include <strong>of</strong>fice space<br />

for the review <strong>of</strong> documentation.<br />

20.8 Lone Working<br />

Lone working should be avoided at all times by suitable liaison with the person in<br />

control <strong>of</strong> the premises to ensure that site personnel are always in attendance.<br />

The planning process for work at height on mobile cranes should take into account<br />

the particular hazards <strong>of</strong> lone working <strong>and</strong> thorough examination at height by lone<br />

workers should not be undertaken.<br />

20.9 Work at Height<br />

Some thorough examination activities on erected mobile cranes may require<br />

competent persons to work at height outside edge protected areas on the mobile<br />

crane structure. The Work at Height Regulations 2005 set out a hierarchy <strong>of</strong> fall<br />

protection measures to be taken when planning work at height.<br />

This means that those planning work at height on mobile cranes should:-<br />

� Avoid work at height wherever possible <strong>and</strong> actively seek solutions to<br />

facilitate this;<br />

� If this is not possible, use “collective” means <strong>of</strong> protection such as guardrails;<br />

� If this is not possible, use “personal” means <strong>of</strong> prevention such as work<br />

restraint;<br />

� If this is not possible, use a personal fall protection system such as a work<br />

positioning system or fall arrest system;<br />

59


� Additionally provide training <strong>and</strong> instruction or take other measures to prevent<br />

any person falling a distance liable to cause personal injury.<br />

Where a risk assessment indicates that a personal fall protection system is required<br />

a work positioning system should always be used in preference to a fall arrest<br />

system. Where the use <strong>of</strong> fall arrest personal fall protection systems are unavoidable<br />

there will be a risk <strong>of</strong> the wearer being left suspended following a fall <strong>and</strong><br />

arrangements must be made to ensure that they can be rescued in a safe <strong>and</strong> timely<br />

manner (See Annex 1).<br />

Where work is being carried out on mobile tower cranes suitable <strong>and</strong> sufficient<br />

arrangements must be put in place for the rescue <strong>of</strong> personnel from height. This<br />

matter is dealt with in the CPA Technical Information Note TIN 013 - Rescue <strong>of</strong><br />

Personnel from height on Tower <strong>Cranes</strong>, which may be downloaded from the CPA<br />

web site.<br />

20.10 Isolation <strong>of</strong> Systems During <strong>Thorough</strong> <strong>Examination</strong><br />

To avoid the risk <strong>of</strong> trapping, crushing, shearing or electrocution during the thorough<br />

examination <strong>of</strong> mechanisms on mobile cranes, all systems should be provided with a<br />

means <strong>of</strong> isolation. Where power is required to a system during examination, a safe<br />

system <strong>of</strong> work should be put in place to mitigate the risks <strong>of</strong> trapping. Such a safe<br />

system <strong>of</strong> work may well involve a “permit to work” <strong>and</strong> adequate communication<br />

between the crane operator <strong>and</strong> other members <strong>of</strong> the thorough examination team.<br />

20.11 Communication Equipment<br />

Personnel carrying out thorough examinations should be provided with an adequate<br />

means <strong>of</strong> communication, <strong>of</strong>ten h<strong>and</strong> held portable radios, to ensure that all<br />

members <strong>of</strong> the thorough examination team can communicate effectively with each<br />

other, the mobile crane operator <strong>and</strong> personnel on the ground.<br />

NOTE: Additional advice on radio communications is given in the CPA Technical Information<br />

Note TIN 017 - Radio Communication for Lifting Operations.<br />

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21.0 Practical Issues for <strong>Thorough</strong> <strong>Examination</strong> on Site<br />

21.1 Introduction<br />

The thorough examination <strong>of</strong> mobile cranes is most effective when carried out in a<br />

workshop or depot yard.<br />

Carrying out a thorough examination <strong>of</strong> a mobile crane away from a depot presents a<br />

particular set <strong>of</strong> issues when compared with carrying out a thorough examination in a<br />

workshop or depot yard. These issues are best addressed at the planning stage<br />

before the crane arrives on site <strong>and</strong> is taken into use. The effective thorough<br />

examination <strong>of</strong> mobile cranes on site will require the cooperation <strong>of</strong> the user <strong>and</strong> an<br />

example <strong>of</strong> a document informing users <strong>of</strong> the issues they should consider when a<br />

thorough examination is being undertaken is given at Annex 4.<br />

21.2 Downtime During <strong>Thorough</strong> <strong>Examination</strong><br />

The main purpose for a mobile crane being on site is to carry out lifting operations as<br />

part <strong>of</strong> the construction process. Site managers are underst<strong>and</strong>ably reluctant to stop<br />

the crane whilst a thorough examination is carried out. If thorough examination<br />

downtime is not scheduled into the construction programme it is pushed to the back<br />

<strong>of</strong> the queue <strong>and</strong> ends up being carried out hurriedly in unsafe conditions such as<br />

poor light.<br />

It is therefore essential that mobile crane owners make clear to those hiring their<br />

cranes that thorough examination is the user’s legal obligation <strong>and</strong> that adequate<br />

downtime must be built into the site programme. Hirers must be informed at the<br />

planning stage <strong>of</strong> the frequency <strong>of</strong> thorough examination <strong>and</strong> probable time required.<br />

In certain circumstances it may be <strong>of</strong> benefit to substitute another crane to allow<br />

thorough examination to be carried out <strong>of</strong>f site.<br />

Construction projects in built up areas <strong>of</strong>ten have environmental restrictions imposed<br />

on them which severely limit working time <strong>and</strong> such restrictions must be taken into<br />

account when planning thorough examinations.<br />

21.3 Site Inductions<br />

Competent persons should have undertaken suitable <strong>and</strong> sufficient health <strong>and</strong> safety<br />

training applicable to their activity before arriving on site. Such training should be<br />

sanctioned by an appropriate industry body for the work function being carried out.<br />

(e.g. SAFed Safety Passport for Engineers undertaking thorough examinations). To<br />

supplement their trade specific health <strong>and</strong> safety training, visiting personnel must<br />

attend an appropriate site specific safety induction focused on the specific hazards<br />

that may be present in the vicinity <strong>of</strong> the intended work,<br />

The induction must be <strong>of</strong> sufficient length to cover the relevant risks, however it is<br />

anticipated that it would normally take 20 – 30 min, <strong>and</strong> where necessary be<br />

specifically prepared by the Principal Contractor in control <strong>of</strong> the site. The time <strong>of</strong> the<br />

induction should be agreed in advance. The induction should be given by the<br />

Principal Contractor’s Manager who will oversee the thorough examination activity.<br />

This will help build relationships <strong>and</strong> a joint underst<strong>and</strong>ing.<br />

21.4 Lines <strong>of</strong> Communication<br />

Those planning <strong>and</strong> carrying out the thorough examination <strong>of</strong> mobile cranes on site<br />

must ensure that they have effective lines <strong>of</strong> communication with the site for initial,<br />

periodic <strong>and</strong> exceptional thorough examinations including preparation. This will avoid<br />

much frustration <strong>and</strong> misunderst<strong>and</strong>ing on both sides.<br />

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21.5 Availability <strong>of</strong> Operators<br />

<strong>Thorough</strong> examination will require the crane to be operated from the control cab<br />

whilst the competent person is examining other parts <strong>of</strong> the crane. Arrangements<br />

must be made to ensure that an operator is available on such occasions.<br />

21.6 Availability <strong>of</strong> <strong>Maintenance</strong> Staff<br />

If the competent person carrying out the thorough examination requires the removal<br />

<strong>of</strong> covers <strong>and</strong> guards to facilitate the through examination <strong>of</strong> concealed parts, the<br />

owner <strong>of</strong> the crane should ensure that suitable personnel are available.<br />

21.7 <strong>Thorough</strong> <strong>Examination</strong> Area<br />

The area in which the thorough examination is being carried out should be <strong>of</strong><br />

adequate size <strong>and</strong> cordoned <strong>of</strong>f to prevent access by persons not directly involved in<br />

the examination.<br />

21.8 Test Area<br />

Careful consideration should be given to the condition <strong>of</strong> any area where tests are to<br />

be conducted. The recommendations provided in the operating instructions for the<br />

crane relate to operations within the rated capacity <strong>and</strong> more stringent requirements<br />

apply when loads are being applied for the purpose <strong>of</strong> testing.<br />

The ground should be level, well consolidated <strong>and</strong> capable <strong>of</strong> withst<strong>and</strong>ing the loads<br />

applied to it. There should be no hidden dangers such as cable ducts, drains, pipes,<br />

back-filled areas, cellars or other subterranean weaknesses. <strong>Cranes</strong> should not be<br />

tested in the vicinity <strong>of</strong> overhead power lines.<br />

The test site should be <strong>of</strong> sufficient size with unrestricted overhead clearance to allow<br />

the unobstructed movement <strong>of</strong> the crane <strong>and</strong> load throughout its test movement, for<br />

example slewing, derricking <strong>and</strong> travelling.<br />

It is preferable that tests are not conducted over high risk areas, for example a public<br />

highway, railway, occupied buildings or in the flight path <strong>of</strong> airports. If due to the<br />

requirements <strong>of</strong> usage this is unavoidable, arrangements should be made with the<br />

appropriate authorities.<br />

If load testing is being carried it must be borne in mind that the crane might not<br />

withst<strong>and</strong> the loading. All personnel not essential to the test should be kept away<br />

from the area. The test area should be cordoned <strong>of</strong>f <strong>and</strong> notices posted prohibiting<br />

unauthorized entry. The site adjacent to the test area should be clear <strong>of</strong> plant <strong>and</strong><br />

property which could inhibit the test.<br />

21.9 Availability <strong>of</strong> Site Facilities<br />

Arrangements should be made to ensure that site management, safety <strong>and</strong> welfare<br />

facilities are available to the competent person <strong>and</strong> any personnel assisting them<br />

both within <strong>and</strong> outside normal working hours. Facilities should include <strong>of</strong>fice space<br />

for the review <strong>of</strong> documentation.<br />

21.10 Lone Working<br />

Lone working should be avoided at all times by suitable liaison with the person in<br />

control <strong>of</strong> the site to ensure that site personnel are always in attendance.<br />

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The planning process for work at height on mobile cranes should take into account<br />

the particular hazards <strong>of</strong> lone working <strong>and</strong> thorough examination at height by lone<br />

workers should not be undertaken.<br />

21.11 Work at Height<br />

Some thorough examination activities on erected mobile cranes may require<br />

competent persons to work at height outside edge protected areas on the mobile<br />

crane structure. The Work at Height Regulations 2005 set out a hierarchy <strong>of</strong> fall<br />

protection measures to be taken when planning work at height.<br />

This means that those planning work at height on mobile cranes should:-<br />

� Avoid work at height wherever possible <strong>and</strong> actively seek solutions to<br />

facilitate this;<br />

� If this is not possible, use “collective” means <strong>of</strong> protection such as guardrails;<br />

� If this is not possible, use “personal” means <strong>of</strong> prevention such as work<br />

restraint;<br />

� If this is not possible, use a personal fall protection system such as a work<br />

positioning system or fall arrest system;<br />

� Additionally provide training <strong>and</strong> instruction or take other measures to prevent<br />

any person falling a distance liable to cause personal injury.<br />

Where a risk assessment indicates that a personal fall protection system is required<br />

a work positioning system should always be used in preference to a fall arrest<br />

system. Where the use <strong>of</strong> fall arrest personal fall protection systems are unavoidable<br />

there will be a risk <strong>of</strong> the wearer being left suspended following a fall <strong>and</strong><br />

arrangements must be made to ensure that they can be rescued in a safe <strong>and</strong> timely<br />

manner (See Annex 1).<br />

Where work is being carried out on mobile tower cranes suitable <strong>and</strong> sufficient<br />

arrangements must be put in place for the rescue <strong>of</strong> personnel from height. This<br />

matter is dealt with in the CPA Technical Information Note TIN 013 - Rescue <strong>of</strong><br />

Personnel from height on Tower <strong>Cranes</strong>, which may be downloaded from the CPA<br />

web site.<br />

21.12 Isolation <strong>of</strong> Systems During <strong>Thorough</strong> <strong>Examination</strong><br />

To avoid the risk <strong>of</strong> trapping, crushing, shearing or electrocution during the thorough<br />

examination <strong>of</strong> mechanisms on mobile cranes, all systems should be provided with a<br />

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means <strong>of</strong> isolation. Where power is required to a system during examination, a safe<br />

system <strong>of</strong> work should be put in place to mitigate the risks <strong>of</strong> trapping. Such a safe<br />

system <strong>of</strong> work may well involve a “permit to work” <strong>and</strong> adequate communication<br />

between the crane operator <strong>and</strong> other members <strong>of</strong> the thorough examination team.<br />

21.13 Communication Equipment<br />

Personnel carrying out thorough examinations should be provided with an adequate<br />

means <strong>of</strong> communication, <strong>of</strong>ten h<strong>and</strong> held portable radios, to ensure that all<br />

members <strong>of</strong> the thorough examination team can communicate effectively with each<br />

other, the mobile crane operator <strong>and</strong> personnel on the ground.<br />

NOTE: Additional advice on radio communications is given in the CPA Technical Information<br />

Note TIN 017 - Radio Communication for Lifting Operations.<br />

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22.0 Lifting Accessories<br />

Lifting Accessories used with mobile cranes fall into two categories:-<br />

� Slings, shackles etc supplied with the crane <strong>and</strong> used solely for the rigging or<br />

maintenance <strong>of</strong> the crane.<br />

� Slings, shackles etc used with the crane for attaching loads to the crane<br />

hook.<br />

Those in the first category are considered to part <strong>of</strong> the crane’s equipment <strong>and</strong><br />

should be thoroughly examined with the crane at the appropriate interval required by<br />

LOLER (not exceeding six months if lifting persons or not exceeding twelve months if<br />

only goods are being lifted).<br />

Those in the second category are defined by LOLER as “lifting accessories” <strong>and</strong><br />

must be thoroughly examined at intervals not exceeding six months.<br />

Lifting points that are permanently attached to the load (e.g. welded or cast-in) are<br />

considered to be part <strong>of</strong> the load, whereas those which can be detached (e.g.<br />

screwed in or bolted on) are considered to be lifting accessories <strong>and</strong> are subject to<br />

thorough examination.<br />

All lifting accessories should be marked with their Working Load Limit (Safe Working<br />

Load) <strong>and</strong> before each use; pre-use checks should be carried out to ensure that they<br />

are in good condition <strong>and</strong> that a current report <strong>of</strong> thorough examination is available. It<br />

is good practice to adopt a tagging system for lifting accessories to indicate if a lifting<br />

accessory has a current report <strong>of</strong> thorough examination. This will enable the person<br />

carrying out the pre-use check to immediately ascertain whether or not the<br />

equipment is “in date”.<br />

Lifting accessories carried on a mobile crane should be stored in a secure weather<br />

tight box or compartment <strong>and</strong> should be listed in a lifting accessory register (see<br />

Annex 7).<br />

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Annex 1 – Work at Height<br />

A1.1.0 Introduction<br />

On average there are five fatalities in the workplace each year due to falls from<br />

height from vehicles, including mobile cranes, with a yearly average <strong>of</strong> 775 non-fatal<br />

major injuries from the same cause. Where working at height is required as part <strong>of</strong><br />

the rigging, use, maintenance <strong>and</strong> thorough examination <strong>of</strong> mobile cranes, it should<br />

be carried out by trained personnel, following careful planning, which includes<br />

adequate assessment <strong>of</strong> the risks involved. This document provides guidance on the<br />

issues involved.<br />

Health <strong>and</strong> Safety legislation requires that safe systems <strong>of</strong> work are in place for all<br />

work activities. The particular references for the requirement to provide safe access,<br />

egress <strong>and</strong> a means <strong>of</strong> safe rescue are:-<br />

� Health <strong>and</strong> Safety at Work etc. Act 1974. - Sections 2 & 3<br />

� Work at Height Regulations 2005<br />

� Provision <strong>and</strong> Use <strong>of</strong> Work Equipment Regulations (PUWER) 1998 –<br />

Regulation 17<br />

� Lifting Operations <strong>and</strong> Lifting Equipment Regulations (LOLER) 1998 –<br />

Regulation 3<br />

� Management <strong>of</strong> Health <strong>and</strong> Safety Regulations 1999 – Regulation 3<br />

� Construction Design <strong>and</strong> Management Regulations 2007<br />

A1.2.0 Responsibility for Planning <strong>of</strong> Work at Height <strong>and</strong> Provision <strong>of</strong><br />

Rescue Resources<br />

The primary duty for ensuring that work at height on a mobile crane is effectively<br />

planned <strong>and</strong> that there are adequate resources for carrying out rescue <strong>of</strong> persons<br />

from height, rests with the organization in control <strong>of</strong> the premises on which any<br />

mobile crane is sited. In the case <strong>of</strong> a construction site this will be the Principal<br />

Contactor, as defined by the Construction (Design <strong>and</strong> Management) Regulations<br />

2007. The Principal Contractor has a responsibility to assess, approve the method <strong>of</strong><br />

work <strong>and</strong> monitor that work is carried out in accordance with the method statement.<br />

Location Responsibility for Planning Work at Height<br />

Construction Sites Principal Contractor<br />

Industrial Premises Person in control <strong>of</strong> the site<br />

Retail Premises Person in control <strong>of</strong> the site<br />

Airports, Docks <strong>and</strong> Railways Person in control <strong>of</strong> the site<br />

Petrochemical Plants Person in control <strong>of</strong> the site<br />

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Domestic Premises Sole responsibility <strong>of</strong> the crane supplier if hiring<br />

directly to a consumer.<br />

In practice it is likely that:-<br />

� Arrangements for work at height during rigging <strong>and</strong> de-rigging will be made by<br />

the mobile crane supplier;<br />

� Arrangements for rescue during rigging <strong>and</strong> de-rigging, maintenance <strong>and</strong><br />

thorough examination on site, or other activities associated with the mobile<br />

crane will be made by the person in control <strong>of</strong> the site. The mobile crane<br />

supplier should, however, also ensure that adequate arrangements are in<br />

place;<br />

� Arrangements for work at height during use <strong>and</strong> the carrying out <strong>of</strong> daily<br />

checks by the operator will be made by the mobile crane supplier;<br />

� Arrangements for work at height during maintenance <strong>and</strong> thorough<br />

examination will be made by the crane supplier in cooperation with the<br />

employer <strong>of</strong> an external competent person (e.g. An Insurance Company);<br />

� Arrangements for rescue during maintenance <strong>and</strong> thorough examination will<br />

be made by the crane supplier in cooperation with the employer <strong>of</strong> an external<br />

competent person (e.g. An Insurance Company).<br />

NOTE: It is vital that there is effective communication between all parties involved.<br />

A1.3.0 Guidance for Work at Height<br />

The Work at Height Regulations 2005 set out a hierarchy <strong>of</strong> fall protection measures<br />

to be taken when planning work at height.<br />

This means that those planning work at height on mobile cranes should:-<br />

� Avoid work at height wherever possible <strong>and</strong> actively seek solutions to<br />

facilitate this;<br />

� If this is not possible, use “collective” means <strong>of</strong> protection such as guardrails;<br />

� If this is not possible, use “personal” means <strong>of</strong> prevention such as work<br />

restraint;<br />

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� If this is not possible, use a personal fall protection system such as a work<br />

positioning system or fall arrest system;<br />

� Additionally provide training <strong>and</strong> instruction or take other measures to prevent<br />

any person falling a distance liable to cause personal injury.<br />

A1.3.1 Elimination <strong>of</strong> work at height<br />

As a primary aim, all tasks associated with work at height on mobile cranes should<br />

be reviewed to see if they can be fully or partially completed at ground level.<br />

Manufacturers should be encouraged to ensure that new designs <strong>of</strong> mobile crane<br />

are developed to reduce the need for work at height to a minimum. Where work at<br />

height cannot be eliminated the following hierarchy should be employed.<br />

A1.3.2 Collective measures<br />

Permanent collective fall prevention measures such as guard rails currently have a<br />

limited application on mobile crane structures. They are sometimes used on ro<strong>of</strong>s<br />

<strong>of</strong> crawler crane machinery housings <strong>and</strong> on the working platforms <strong>of</strong> some<br />

wheeled mobile cranes.<br />

When purchasing new mobile cranes, consideration should be given to the<br />

collective measures provided by the manufacturers as part <strong>of</strong> the purchase<br />

evaluation process. Manufacturers should be strongly encouraged to incorporate<br />

collective measures into new designs <strong>of</strong> mobile crane to enable rigging, use <strong>and</strong><br />

maintenance to be carried out safely, with a minimal need for the use <strong>of</strong> personal<br />

fall protection systems.<br />

Other collective measures that can be employed include the use <strong>of</strong> other<br />

equipment such as access gantries, tower scaffolds <strong>and</strong> MEWPs. Care needs to<br />

be taken, particularly in the case <strong>of</strong> MEWPs where the operation should be<br />

adequately planned <strong>and</strong> operators must be adequately trained <strong>and</strong> familiarised with<br />

the specific model <strong>of</strong> MEWP to be used.<br />

Detailed guidance on the safe use <strong>of</strong> MEWPs is given in BS8460:2005 – Safe use<br />

<strong>of</strong> MEWPs – Code <strong>of</strong> practice<br />

A1.3.3 Personal Fall Prevention<br />

Collective fall prevention is <strong>of</strong>ten difficult to provide when accessing mobile crane<br />

structures. Therefore some <strong>of</strong> the work will be carried out using personal fall<br />

prevention equipment. This will normally fall into one <strong>of</strong> two types:-<br />

� Work restraint systems<br />

� Work positioning systems<br />

A1.3.3.1 Work restraint systems<br />

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Figure 1 - Work Restraint System<br />

Work restraint systems are designed to prevent personnel from<br />

reaching an unprotected edge <strong>and</strong> falling. By definition they restrain<br />

the wearer by restricting movement <strong>and</strong> may be <strong>of</strong> limited value when<br />

working on the crane structure.<br />

A1.3.3.2 Work positioning systems<br />

Work positioning systems can provide full or partial support to<br />

personnel <strong>and</strong> prevent them from falling whilst carrying out tasks in<br />

one location. They allow the wearer to work safely with both h<strong>and</strong>s.<br />

Work positioning systems used on mobile cranes should always be<br />

combined with a fall arrest system to provide protection at the location<br />

where the work positioning system will be used. The fall arrest system<br />

will provide protection whilst the wearer is moving to <strong>and</strong> from, the<br />

location where the work positioning system will be used.<br />

A1.3.4 Collective Fall Protection<br />

Figure 2 - Work Positioning System<br />

There are a number <strong>of</strong> proprietary collective fall protection systems, such as nets or<br />

airbags on the market. These should be carefully evaluated to ensure that they are<br />

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appropriate <strong>and</strong> effective solutions for the particular issues associated with working<br />

at height on mobile cranes.<br />

A1.3.5 Personal Fall Protection<br />

If it is not possible or appropriate to use collective or personal fall prevention or<br />

collective fall protection systems, personal fall protection should be used to mitigate<br />

the effects <strong>of</strong> any fall. This will generally be the use <strong>of</strong> personal fall arrest systems<br />

Figure 3 - Fall Arrest System<br />

Fall arrest systems will reduce the consequences <strong>of</strong> a fall where the wearer is<br />

working outside a protected edge, such as the confines <strong>of</strong> any guardrails. A two<br />

lanyard system will allow movement around a structure. When fall arrest systems<br />

are used, a vital part <strong>of</strong> the planning process is consideration <strong>of</strong> arrangements for<br />

the rescue <strong>of</strong> persons suspended in the fall arrest system after a fall.<br />

Suspension trauma can occur even if a person has only been suspended at height<br />

for a short period <strong>of</strong> time, particularly if they are motionless (See Section 9.1).<br />

When using fall arrest systems it is important that the anchor point is as high as<br />

possible to ensure that the “fall factor” which provides an indication <strong>of</strong> the length<br />

<strong>and</strong> severity <strong>of</strong> a fall, is kept as low as possible. The “fall factor” can also be<br />

reduced by the use <strong>of</strong> a proprietary shortening device (See Figure 4).<br />

Reducing fall factors is vital where personnel using fall arrest systems are working<br />

at low heights above the ground, as is <strong>of</strong>ten the case with mobile cranes. If an<br />

anchor point is level with the feet <strong>of</strong> the wearer the minimum free space required<br />

above the ground with a 1.5m energy absorbing lanyard is 5.75m, according to<br />

Table F1 <strong>of</strong> BS 8437.<br />

Further information on “fall factors” is given in Clause 9.1.3.1 <strong>of</strong> BS 8437:2005 -<br />

Code <strong>of</strong> practice for selection, use <strong>and</strong> maintenance <strong>of</strong> personal fall protection<br />

systems <strong>and</strong> equipment for use in the workplace.<br />

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A1.3.6 Anchor Points<br />

Figure 4 - Lanyard Shortening Device<br />

All personal fall protection systems require connection to an anchor point. It is<br />

essential that all anchor points have an adequate margin <strong>of</strong> strength <strong>and</strong> stability to<br />

withst<strong>and</strong> the dynamic <strong>and</strong> static forces that could be applied to them in service.<br />

Anchor points for fall arrest systems will require a greater capacity than those for<br />

work restraint or work positioning systems. Manufacturers should be consulted on<br />

the designation <strong>of</strong> suitable & sufficient anchor points.<br />

Single person anchor points for fall arrest systems should be designed to resist a<br />

minimum static force <strong>of</strong> 12kN. This includes a safety factor <strong>of</strong> 2 to allow for the<br />

dynamic <strong>and</strong> static forces that could be applied to them in service. If two or more<br />

users are to be connected to the same anchor the minimum static strength <strong>of</strong> the<br />

anchor should be increased to 14kN for two persons <strong>and</strong> 16kN for three person<br />

use.<br />

Specifications for the installation <strong>and</strong> testing <strong>of</strong> anchors are given in:-<br />

BS 7883:1997 - Code <strong>of</strong> practice for application <strong>and</strong> use <strong>of</strong> anchor devices<br />

conforming to BS EN 795.<br />

Where personal fall protection systems are required, manufacturers should be<br />

encouraged to provide <strong>and</strong> designate suitable & sufficient anchor points to which<br />

lanyards etc. can be fastened. On new machine purchases the provision <strong>of</strong> anchor<br />

points should be made a condition <strong>of</strong> order <strong>and</strong> manufacturer’s advice should be<br />

sought on the availability <strong>of</strong> anchor point kits for retr<strong>of</strong>itting on existing cranes.<br />

With all types <strong>of</strong> personal fall protection equipment it is essential that the following<br />

points are considered during planning for work at height:-<br />

� Correct equipment for the application is selected;<br />

� Personnel are trained <strong>and</strong> assessed as competent in the correct adjustment,<br />

use, care <strong>and</strong> recorded checking <strong>of</strong> fall protection equipment;<br />

� Suitable anchor points on the structure are identified;<br />

� Arrangements are made for the inspection <strong>and</strong> maintenance <strong>of</strong> the<br />

equipment.<br />

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Detailed guidance is given in BS 8437:2005 - Code <strong>of</strong> practice for selection, use<br />

<strong>and</strong> maintenance <strong>of</strong> personal fall protection systems <strong>and</strong> equipment for use in the<br />

workplace.<br />

A1.3.7 Ladders<br />

The basic configuration <strong>of</strong> mobile cranes means that it may not be possible to<br />

provide means <strong>of</strong> access to parts <strong>of</strong> the crane with collective fall protection,<br />

particularly when a crane is on site, rather than in a depot. Consequently fixed<br />

ladders (attached to the crane structure) <strong>and</strong> portable ladders are <strong>of</strong>ten used.<br />

Where portable ladders are used they should be <strong>of</strong> sound construction, with a<br />

broad base <strong>and</strong> fixed to provide effective restraint against slipping. Research has<br />

shown that “footing” <strong>of</strong> ladders by a second person is <strong>of</strong> limited value. Where<br />

personnel are transferring from a ladder to the crane structure there must be<br />

sufficient projection <strong>of</strong> the ladder (at least 1m or three rungs) beyond the l<strong>and</strong>ing<br />

level to provide adequate h<strong>and</strong>holds during transfer.<br />

Suitable Ladder Automatic Ladder Latch with Anchor Point<br />

Personnel using ladders must be adequately trained in the selection, use <strong>and</strong> preuse<br />

checking <strong>of</strong> ladders. See Sections 11 <strong>and</strong> 13.<br />

Additional guidance is given in the following HSE publications:-<br />

� INDG402 - Safe use <strong>of</strong> ladders <strong>and</strong> stepladders: An employers’ guide<br />

� INDG403 - A toolbox talk on leaning ladder <strong>and</strong> stepladder safety<br />

� INDG405 - Top tips for ladder safety(Pocket Card)<br />

A1.4.0 Guidance for Rescue From Height on <strong>Mobile</strong> <strong>Cranes</strong><br />

Typical methods <strong>and</strong> items for consideration in the planning for rescue from height on<br />

mobile cranes are as follows:-<br />

A1.4.1 Recovery from Suspension During Rigging or De-rigging<br />

If the work at height during rigging or de-rigging only involves low level working it<br />

may be adequate to utilise other members <strong>of</strong> the rigging team to support the<br />

suspended person. This must however be carefully evaluated at the planning<br />

stage, taking into account the potential height <strong>of</strong> the suspended person above the<br />

rescuers <strong>and</strong> the number <strong>and</strong> physique <strong>of</strong> the rescuers.<br />

Where rescue by other members <strong>of</strong> the rigging team is not practicable other means<br />

must be employed. This could include:-<br />

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� A system provided by the Principal Contractor;<br />

� A MEWP;<br />

� A teleh<strong>and</strong>ler with a non-integrated platform;<br />

� A crane with a man riding cage;<br />

� A proprietary rescue system.<br />

In planning for rescue from height, reliance should not be placed on the use <strong>of</strong> the<br />

Emergency services without first consulting those services<br />

Suspension in a harness for a period <strong>of</strong> time (<strong>of</strong>ten as little a ten minutes)<br />

without moving may give rise to “suspension trauma” which leads to pooling<br />

<strong>of</strong> blood in the veins <strong>of</strong> the lower limbs. This can cause disturbance to the<br />

circulatory system leading to damage <strong>of</strong> the vital organs. When rescuing a<br />

suspended person care must be taken to avoid moving them into a horizontal<br />

position as this can cause a massive flow <strong>of</strong> venous blood to the heart, which<br />

cannot cope, <strong>and</strong> this can cause potentially fatal cardiac abnormalities.<br />

Additional information on suspension trauma is given in Annex D <strong>of</strong> BS 8437:2005 -<br />

Code <strong>of</strong> practice for selection, use <strong>and</strong> maintenance <strong>of</strong> personal fall protection<br />

systems <strong>and</strong> equipment for use in the workplace.<br />

A1.4.2 During <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong> <strong>Examination</strong> <strong>of</strong> the <strong>Mobile</strong> Crane<br />

In this situation the method described in 9.1 can also be used, it does however rely<br />

on having a trained person on site at all times whilst fall arrest systems are being<br />

used.<br />

A1.4.3 Injury or Medical Crisis<br />

In this situation the injured person should be lowered to a suitable position where<br />

first aid can be administered in accordance with the site emergency plan.<br />

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Annex 2 - Example <strong>of</strong> a Typical Safe System <strong>of</strong> Work for <strong>Thorough</strong><br />

<strong>Examination</strong> Activities<br />

1. Introduction<br />

This safe system <strong>of</strong> work considers the hazards <strong>and</strong> risks when undertaking the<br />

examination <strong>of</strong> mobile <strong>and</strong> crawler cranes. As a necessity <strong>of</strong> examination, the<br />

plant will have to be manoeuvred to prove satisfactory function <strong>and</strong> operation.<br />

This creates added risks such as falling from plant, being trapped, crushed or<br />

struck by plant movement. The safe system is to raise awareness <strong>of</strong> the<br />

hazards <strong>and</strong> therefore reduce the risks involved, so far as is reasonably<br />

practicable.<br />

2. Scope<br />

The guidance covers work associated with the examination <strong>of</strong> all types <strong>of</strong><br />

mobile <strong>and</strong> crawler crane <strong>and</strong> lifting accessory.<br />

3. Legislation <strong>and</strong> other publications<br />

3.1 Legislation<br />

The following is a summary <strong>of</strong> relevant legislation, including:<br />

a. Health <strong>and</strong> Safety at Work Act 1974<br />

b. The Supply <strong>of</strong> Machinery (Safety) Regulations 2008<br />

c. Provision <strong>and</strong> Use <strong>of</strong> Work Equipment Regs (PUWER 98) 1998<br />

d. Lifting Operations <strong>and</strong> Lifting Equipment Regulations (LOLER) 1998<br />

e. Management <strong>of</strong> Health <strong>and</strong> Safety at Work Regulations 1999<br />

f. Work at Height Regulations 2005 (as amended)<br />

This list is not exhaustive <strong>and</strong> reference may need to be made to other<br />

Legislation as applicable.<br />

3.2 Other relevant guidance includes:<br />

4. Hazards<br />

a. Safe use <strong>of</strong> <strong>Cranes</strong>: BS 7121 Pts 1, 2 & 3.<br />

b. Safe use <strong>of</strong> ladders, step ladders & trestles, HS(G) 31.<br />

c. In-house procedures <strong>and</strong> instructions.<br />

d. Personal Protective Equipment.<br />

This list is not exhaustive <strong>and</strong> reference may need to be made to other<br />

documents.<br />

74


4.1 Anticipating the Consequences <strong>of</strong> Actions<br />

Many accidents occur because <strong>of</strong> a lack <strong>of</strong> planning <strong>and</strong>/or consideration <strong>of</strong> what<br />

could<br />

happen as a result <strong>of</strong> actions on site.<br />

4.2 Known Hazards<br />

Examples <strong>of</strong> how injury can occur when undertaking the examination <strong>of</strong> mobile<br />

<strong>and</strong> crawler cranes:<br />

a. Trapping / Crushing.<br />

b. Falling<br />

c. Being struck<br />

d. Electrical shock<br />

4.3 Hazard details<br />

4.3.1 Trapping <strong>and</strong> Crushing points:<br />

There are many trapping points to consider when undertaking the<br />

examination <strong>of</strong> mobile <strong>and</strong> crawler cranes. Trapping hazards are present at<br />

following areas:<br />

a. Slewing <strong>of</strong> cranes: Trapping can occur between slew ring <strong>and</strong><br />

its attachments ( ladders, underside <strong>of</strong> jibs, counterweight<br />

attachments, etc.) <strong>and</strong> also between adjacent plant <strong>and</strong><br />

building structure. At slew ring drive systems.<br />

b. Luffing/derricking <strong>of</strong> cranes: At rope drums <strong>and</strong> divertor<br />

sheaves (h<strong>and</strong>s or clothing being caught between ropes <strong>and</strong><br />

rope drums <strong>and</strong> divertor sheaves); in machinery housings or<br />

apex assemblies. At jib pivot <strong>and</strong> articulating points. Moving<br />

counter balance systems.<br />

c. Telescoping Jibs: At jib entry points <strong>and</strong> jib attachments.<br />

d Hoisting/lowering <strong>of</strong> ropes: At rope drums <strong>and</strong> rope divertor<br />

sheaves, open gears <strong>and</strong> pulley systems. Rotating machinery<br />

ie. brake drums, couplings, shafts, winches, etc.<br />

e With mobile <strong>and</strong> crawler cranes: Along travel routes - being<br />

trapped by wheels or track drives. Being trapped against<br />

plant <strong>and</strong> machinery <strong>and</strong> adjacent building or plant<br />

structures.<br />

g. Between plant <strong>and</strong> site buildings or ground in the event <strong>of</strong><br />

plant overturning during examination.<br />

4.3.2 Falling:<br />

Generally falls can occur at any time when undertaking the<br />

75


examination <strong>of</strong> mobile <strong>and</strong> crawler cranes. By virtue <strong>of</strong> their<br />

construction, climbing <strong>and</strong> access to areas above ground are a<br />

necessity. The risk from falling is present when:<br />

a. Climbing jibs, machine structures <strong>and</strong> slipping from ladders<br />

<strong>and</strong> plant structure.<br />

b. Using ladders <strong>and</strong> other means <strong>of</strong> access.<br />

c. Slipping on oil/grease on plant structure <strong>and</strong> ground,<br />

unstable or uneven ground conditions.<br />

d. Tripping over obstacles on items <strong>of</strong> plant being examined,<br />

<strong>and</strong> items at ground level on site.<br />

e. Deteriorating weather conditions. i.e. ice, rain <strong>and</strong> wind<br />

present.<br />

4.3.3 Being struck:<br />

a. By moving parts <strong>of</strong> plant undergoing examination ie jib<br />

structures, slew arrangements, outrigger movement, etc.<br />

b. By load hooks <strong>and</strong> suspended loads on cranes.<br />

c. By wheels <strong>and</strong> track drives on mobile plant.<br />

d. By other plant, <strong>and</strong> mobile systems in operation at site.<br />

e. By chain slings <strong>and</strong> lifting beams <strong>and</strong> frames suspended from<br />

cranes.<br />

f. By failure <strong>of</strong> plant under examination ie. loads being dropped,<br />

failure <strong>of</strong> plant structures.<br />

g. From projections on machinery <strong>and</strong> buildings.<br />

4.3.4 Other hazards include:<br />

a. Risk <strong>of</strong> electrical shock from live equipment <strong>and</strong> poorly<br />

maintained systems. <strong>Cranes</strong> being examined striking<br />

overhead electric power lines.<br />

b. Fumes <strong>and</strong> dust from site work.<br />

c. Catch points - clothing or rings being caught on protrusions.<br />

d. Noise - from plant being examined <strong>and</strong> adjacent work processes.<br />

e. Vibration - from cranes being examined.<br />

f. Burns - hot surfaces on cranes being examined.<br />

5. Safe working on cranes - general<br />

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Prior to examination <strong>of</strong> cranes:<br />

5.1 Access & Egress<br />

The Competent Person shall make their presence known to a responsible<br />

person at the location. At the end <strong>of</strong> his visit the Competent Person shall<br />

advise that person that they are leaving the site.<br />

5.2 Unoccupied Premises<br />

Under no circumstance shall the Competent Person work alone at<br />

unoccupied premises or carry out any examination at premises where no<br />

member <strong>of</strong> the clients staff ( or other responsible person) is present.<br />

5.3 Appropriate Clothing<br />

Competent Persons shall wear suitable protective clothing <strong>and</strong> equipment<br />

eg. Safety helmet, boiler suit, gloves, suitable safety boots or shoes, <strong>and</strong><br />

safety harness. All shall be maintained in good condition <strong>and</strong> properly<br />

worn.<br />

5.4 Personal Protection & Safety Equipment<br />

Other personal protection <strong>and</strong> safety equipment shall be worn according<br />

to the site conditions <strong>and</strong> clients site safe systems <strong>of</strong> work. eg. eye<br />

protection, hearing protection, high visibility clothing, personal buoyancy<br />

equipment, <strong>and</strong> respiratory protective equipment.<br />

5.5 <strong>Inspection</strong> Plan<br />

Competent Persons shall plan the sequence <strong>of</strong> their examination prior to<br />

commencement. This is essential when undertaking the examination <strong>of</strong><br />

mobile <strong>and</strong> crawler cranes, with regard to health <strong>and</strong> safety.<br />

Planning should include the following:<br />

a. Suitable <strong>and</strong> satisfactory on site procedures must be in place <strong>and</strong><br />

capable <strong>of</strong> being initiated, in the event <strong>of</strong> an accident.<br />

b. Briefing <strong>of</strong> the responsible person on site <strong>and</strong> plant driver/operator<br />

as to the sequence <strong>of</strong> examination.<br />

c. Banksman (where used) <strong>and</strong> plant driver/operator must fully<br />

underst<strong>and</strong> the examination procedure <strong>and</strong> the system <strong>of</strong> h<strong>and</strong><br />

signals to be used where applicable. All personnel must underst<strong>and</strong><br />

the emergency signals <strong>and</strong> procedures.<br />

d. <strong>Examination</strong>s <strong>of</strong> mobile plant should be away from regular site<br />

traffic <strong>and</strong> site routes. This will reduce the risk from being struck by,<br />

<strong>and</strong> striking, other site traffic <strong>and</strong> site personnel.<br />

e. Ensure ground conditions are sound <strong>and</strong> will fully support the plant<br />

to be inspected in all examination positions, without risk <strong>of</strong><br />

overturning due to ground instability.<br />

77


f. Position <strong>of</strong> plant being examined to be well away from edges <strong>of</strong><br />

excavations, <strong>and</strong> overhead electric power lines.<br />

g. Ensure adequate clearance, <strong>and</strong> sufficient operating space,<br />

between plant being examined <strong>and</strong> adjacent fixtures to prevent<br />

trapping <strong>and</strong> crushing hazard.<br />

5.6 Isolation<br />

When a lifting machine with a travelling or slewing motion is used,<br />

an obstructed passageway at least 600mm (2ft) wide must be<br />

maintained between the moving parts <strong>of</strong> the machine <strong>and</strong> any<br />

nearby fixture." This st<strong>and</strong>ard should be applied to the inspection <strong>of</strong><br />

all lifting machines with a travelling or slewing motion.<br />

Where plant <strong>and</strong> machinery needs to be isolated for inspection purposes<br />

the Engineer Surveyor shall ensure power is isolated from the plant.<br />

This should consist <strong>of</strong> switching <strong>of</strong>f power where required <strong>and</strong> displaying<br />

warning notices at the isolation points.<br />

5.7 Operation <strong>of</strong> Plant<br />

Operation <strong>of</strong> cranes should be carried out by the competent operators<br />

except where it is necessary for the Competent Person to do so as part <strong>of</strong><br />

his examination.<br />

5.7.1 Unrestricted View<br />

The driver/operator <strong>of</strong> the crane must have a clear view <strong>of</strong><br />

operations. Where this is not possible a banksman must be used.<br />

5.7.2 Competent Person Restrictions<br />

Competent Persons should not drive or operate motions <strong>of</strong> plant for<br />

any other purpose than the minimum amount strictly necessary to<br />

carry out the examination.<br />

Where it is necessary for the Competent Person to operate cranes<br />

themselves they should:<br />

a. obtain prior permission <strong>of</strong> a responsible person at the<br />

location.<br />

b. take all reasonable care during the operation <strong>of</strong> the plant.<br />

c. satisfy themselves that all reasonable safety precautions have<br />

been taken.<br />

d. ensure the crane is left in a safe condition at the end <strong>of</strong> the<br />

examination.<br />

5.7.3 Client Responsibility<br />

Under no circumstance shall a Competent Person operate any<br />

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crane if they have any doubt as to their own ability to do so or the<br />

authority <strong>of</strong> the person giving them permission to do so. In all such<br />

cases the Competent Person should request the client provides a<br />

competent operator.<br />

5.8 Notification <strong>of</strong> Appropriate Authorities<br />

If a crane is to slew over a public highway, river or railway the Competent<br />

Person should ensure that the client has notified the appropriate<br />

authority.<br />

5.9 Water Borne<br />

With cranes on water borne craft information should be obtained<br />

regarding the amount <strong>of</strong> list <strong>and</strong> freeboard allowable under both safe<br />

working load <strong>and</strong> overload conditions, from a competent person or<br />

authority experienced in crane design <strong>and</strong> stability <strong>of</strong> craft. Plus how far<br />

the crane is derated from l<strong>and</strong> based ratings whilst on the barge or<br />

pontoon.<br />

5.10 Environmental Conditions<br />

Careful attention should be given to cranes operating in situations where<br />

they are likely to be affected by the weather. Certain weather conditions<br />

such as strong wind, heavy rains, ice or snow can impose loads on a<br />

crane <strong>and</strong> adversely affect the safety <strong>of</strong> crane operations. Never<br />

undertake examinations when the crane or load cannot be easily seen<br />

due to limitations on visibility or when coated with ice or snow. The crane<br />

should not be operated in wind speeds in excess <strong>of</strong> those specified in the<br />

operating instructions for the equipment.<br />

5.11 Outriggers<br />

<strong>Cranes</strong> fitted with outriggers are not fully stable until the outriggers are<br />

set in accordance with the manufacturers instructions. When used,<br />

always ensure outriggers are fully extended to their full extension<br />

position.<br />

6 During examinations<br />

6.1 Safe Access<br />

Always use a safe means <strong>of</strong> access to reach parts <strong>of</strong> the crane requiring<br />

examination above ground level, i.e. properly secured ladders or access<br />

platforms. When working above ground level a safety harness should be<br />

worn by the Competent Person where there is an identifiable risk <strong>of</strong><br />

falling.<br />

6.2 Climbing Precautions<br />

Keep a good foot <strong>and</strong> h<strong>and</strong>hold when climbing crane structures. Watch<br />

for obstacles, protrusions, oil <strong>and</strong> grease deposits, ice <strong>and</strong> water which<br />

may cause a tripping or slipping hazard.<br />

6.3 Ladders<br />

79


If long, extension or step ladders are used during the course <strong>of</strong> an<br />

examination they must be in good condition <strong>and</strong> free from defects <strong>and</strong><br />

damage. Wooden ladders must not be painted as the paint may hide<br />

defects. Always ensure ladders are stable <strong>and</strong> securely fixed. When<br />

using long or extension ladders they must be securely fixed or supported<br />

<strong>and</strong> be on a level firm surface. They must extend at least 1 metre above<br />

the highest level to be accessed. Step ladders must be long enough to<br />

enable the Competent Person to examine the crane <strong>and</strong> have an<br />

adequate h<strong>and</strong>hold.<br />

6.4 Other Hazards<br />

Competent Persons should not position themselves close to open<br />

excavations, pits or waters edge during the course <strong>of</strong> examination.<br />

6.5 Moving Plant & Parts<br />

When a crane is being moved during an examination the Competent<br />

Person should position themselves clear <strong>of</strong> all moving parts <strong>and</strong> have a<br />

clear view <strong>of</strong> the driver/operator. Where this is not possible a banksman<br />

should be used to relay the Competent Persons signals to the<br />

driver/operator.<br />

6.6 Wheels & Tracks<br />

St<strong>and</strong> well clear <strong>of</strong> wheels <strong>and</strong> tracks when the crane is being moved.<br />

6.7 Other Plant<br />

Be aware <strong>of</strong> other plant moving on site adjacent to the crane being<br />

examined.<br />

6.8 Rope <strong>Inspection</strong>s<br />

Always wear gloves when inspecting hoist ropes, etc. If it is necessary to<br />

examine ropes when they are moving ensure they are moving at slow<br />

speed <strong>and</strong> away from hoist <strong>and</strong> winch drums.<br />

6.9 Suspended Loads<br />

Never st<strong>and</strong> beneath suspended loads or parts <strong>of</strong> the crane which could<br />

descend.<br />

6.10 Buoyancy Aids<br />

Buoyancy aids/life jackets must be worn when undertaking examinations<br />

on waterborne cranes, situated on barges, boats or pontoons, or where<br />

adjacent to waters edge.<br />

6.11 Trapping<br />

A Competent Person should always position themselves where they will<br />

not be trapped between adjacent fixed structures <strong>and</strong> the crane being<br />

examined.<br />

80


6.12 Crushing<br />

Keep h<strong>and</strong>s, arms, feet <strong>and</strong> head clear <strong>of</strong> any potential trapping or<br />

crushing points, i.e. crane pivot <strong>and</strong> articulating points, sliding <strong>and</strong><br />

telescoping components, open rotating parts.<br />

6.13 Pendant Controls<br />

When working at height on a crane, ensure that any pendant or remote<br />

controls are not within reach <strong>of</strong> anyone who could inadvertently operate<br />

the crane during examination.<br />

6.14 Securing Ladders<br />

Ensure that when resting ladders against cranes, the mechanisms upon<br />

which the ladders are resting are not capable <strong>of</strong> movement (i.e. braking<br />

applied, mechanism chocked, etc), during that part <strong>of</strong> the examination.<br />

7 Permit to work<br />

Some clients operate a "Permit to Work" system when work is required on<br />

certain cranes. The permit to work system is an extension to the safe system <strong>of</strong><br />

work when written authorisation is required before a particular job can be<br />

started.<br />

8 Summary<br />

The preceding sections outline the main considerations to achieve a safe<br />

system <strong>of</strong> work when undertaking examinations <strong>of</strong> mobile <strong>and</strong> crawler cranes.<br />

Physical layout <strong>and</strong> operational facilities vary considerably depending on<br />

client’s premises <strong>and</strong> the crane being examined. Therefore, the safe system <strong>of</strong><br />

work must be adapted to take into account the particular characteristics <strong>and</strong><br />

situation <strong>of</strong> the crane being examined <strong>and</strong> the working environment in which it<br />

is operating.<br />

81


Annex 3 – Example <strong>of</strong> a Defined Scope <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong> for<br />

<strong>Mobile</strong> <strong>Cranes</strong><br />

Generic Element<br />

Resources<br />

Regulations<br />

(ACOP <strong>and</strong><br />

Guidance)<br />

Documentation<br />

Tools Torch<br />

Provision <strong>and</strong> Use <strong>of</strong> Work Equipment Regulations 1998<br />

Lifting Operation <strong>and</strong> Lifting Equipment Regulations 1998<br />

BS 7121 Parts 1, 2 & 3<br />

Health & Safety Technical Documentation<br />

� Safe systems <strong>of</strong> work<br />

� Risk assessments<br />

Rope Gauge<br />

Vernier Calliper<br />

Mirror<br />

H<strong>and</strong> Tools<br />

Engineers Tape/Rule<br />

Sheave Gauge<br />

Requirements Crane Location<br />

Crane Description<br />

Crane Identification<br />

Safe Working Load<br />

Crane Operator<br />

Authority/Permit to Work<br />

82


<strong>Examination</strong> Areas<br />

Area Element Requirement<br />

Jib (Strut)<br />

Jib (Telescopic)<br />

Jib (Fly)<br />

Sheaves<br />

Ropes (Running<br />

<strong>and</strong> Static)<br />

Hoist <strong>and</strong><br />

Luffing<br />

Mechanism<br />

Hook Block<br />

Slew<br />

Mechanism<br />

Identification Correct Markings<br />

Section Assembly <strong>and</strong> Identification Correct Markings<br />

Jib Length/RCI/RCL Match Correct Markings<br />

Structural Integrity Assessment <strong>of</strong> Construction<br />

Welds, Fixings <strong>and</strong> Fastenings Security <strong>and</strong> Assessment <strong>of</strong> Connections<br />

Heel Pins/Bushes Wear, Cracking, Lubrication<br />

Jib Stops Conditions<br />

Back Stays <strong>and</strong> Mountings Security <strong>and</strong> Assessment <strong>of</strong> Connections<br />

Jib Length/RCI/RCL Match Correct Markings, Extension Markings<br />

Radius/Load Indicator Correct Markings<br />

Structural Integrity Assessment <strong>of</strong> Construction<br />

Welds, Fixings <strong>and</strong> Fastenings Security <strong>and</strong> Assessment <strong>of</strong> Connections<br />

Heel Pins/Bushes Wear, Cracking, Lubrication<br />

Wear Pad Condition<br />

Jib Stops Condition<br />

Extension Chains/Ropes/Sheaves<br />

Hydraulics:-<br />

Condition <strong>and</strong> Wear<br />

� Cylinders Wear <strong>and</strong> Leakage<br />

� Retention Pins/Bushes Wear, Cracking, Lubrication<br />

� Pipes, Unions, Couplings Security, Corrosion, Leakage<br />

� Reservoir Oil Levels Correct Levels<br />

Structural Integrity Assessment <strong>of</strong> Construction<br />

Welds, Fixings <strong>and</strong> Fastenings Security <strong>and</strong> Assessment <strong>of</strong> Connections<br />

Pins/Bushes Wear, Cracking, Lubrication<br />

Size Correct Sizes<br />

Condition Wear, Damage<br />

Pins/Bushes Wear, Cracking, Lubrication<br />

Condition Damage, Broken Str<strong>and</strong>s<br />

Terminations Security <strong>of</strong> Terminations<br />

Drums Condition<br />

Clutches <strong>and</strong> Brakes Damage, Wear<br />

Bridle Assembly Condition<br />

Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

Hook<br />

Wear, Cracking<br />

Swivel Bearing<br />

Wear, Cracking, Lubrication<br />

Safety Clip Security <strong>of</strong> Clip<br />

Markings – SWL, ID Correct Markings<br />

Driving Motor Mounting Assessment <strong>of</strong> Conditions<br />

Gear Integrity Wear, Cracking, Lubrication<br />

Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

Brake Condition Wear<br />

Slew lock (travelling) Function <strong>and</strong> condition<br />

Slew bearing Wear, lift <strong>and</strong> lubrication<br />

83


Structures Structural Integrity Assessment <strong>of</strong> Construction<br />

Welds, Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

Counterweight Counterweights Security <strong>and</strong> Adequacy<br />

Locking <strong>and</strong> h<strong>and</strong>ling system Function <strong>and</strong> Condition<br />

Markings Visible <strong>and</strong> Adequate<br />

Integrity Assessment <strong>of</strong> construction<br />

Chassis Structural Integrity Assessment <strong>of</strong> Construction<br />

Welds, Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

Outriggers Structural Integrity Assessment <strong>of</strong> Construction<br />

Welds, Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

Outrigger foot pads <strong>and</strong> spreader mats Condition<br />

Wear Pads Condition<br />

Markings (outrigger beam, hazard<br />

warnings etc)<br />

Visible <strong>and</strong> Adequate<br />

Hydraulics:-<br />

� Rams Wear <strong>and</strong> Leakage<br />

� Retention Pins/Bushes Wear, Cracking, Lubrication<br />

� Pipes, Unions, Couplings Security, Corrosion, Leakage<br />

� Reservoir Oil Levels Correct Levels<br />

Running Gear Tyres Damage, General Condition<br />

(Wheeled <strong>and</strong> Axle Mountings Assessment <strong>of</strong> Construction<br />

Tracked) Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

Track Pads Condition<br />

Track Tension Condition<br />

Drive Sprockets Wear, Damage<br />

Steering<br />

Drive Motor:-<br />

Condition<br />

� Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

� Drive Chain Condition<br />

Running Gear<br />

(Road Going)<br />

Wheels Wear, Damage<br />

Axles, Suspension <strong>and</strong> Locks Function, Wear, Cracking<br />

Bearings <strong>and</strong> Bushes Wear, Lubrication<br />

Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

Super Structure Body Panels<br />

� Cab<br />

Condition<br />

� Doors Functional<br />

� Windows Damage<br />

� Seat Assessment <strong>of</strong> Construction<br />

Running Boards:-<br />

� Deck Condition<br />

� Fixings <strong>and</strong> Fastenings Security <strong>of</strong> Connections<br />

84


Operation Power Unit:-<br />

Controls:-<br />

Brakes:-<br />

� Guarding/Covers Condition<br />

� Cables Damage, Security <strong>of</strong> Connection<br />

� Markings Correct Markings<br />

� Function <strong>and</strong> Operation Correct Functioning<br />

� Operation Correct Operation <strong>and</strong> Effectiveness<br />

Horn Function<br />

Lights<br />

Windscreen Wipers<br />

85<br />

Function <strong>and</strong> Condition<br />

Function <strong>and</strong> Condition<br />

RCI Condition Security<br />

Boom Angle Accuracy <strong>and</strong> Orientation<br />

Radius Accuracy<br />

Boom length Accuracy<br />

Load <strong>and</strong> Capacity Accuracy<br />

Warnings (audible <strong>and</strong> visual) Function <strong>and</strong> Condition (approach <strong>and</strong> limit)<br />

Display Function <strong>and</strong> Condition (legibility)<br />

RCL<br />

Condition Assessment <strong>of</strong> Construction<br />

Operation (Test) Correct Operation <strong>and</strong> Accuracy<br />

Setting Correct Setting<br />

Override Switches<br />

Limiting Devices:-<br />

Function <strong>and</strong> Condition<br />

� Over hoist Function <strong>and</strong> Condition<br />

� Over lower Function <strong>and</strong> Condition<br />

SWL<br />

Load Chart Present <strong>and</strong> Correct<br />

Markings Present, Correct <strong>and</strong> Legible<br />

Manufacturer’s CE Mark Present <strong>and</strong> Correct<br />

Plate<br />

Serial Number<br />

Present <strong>and</strong> Correct<br />

Model Number<br />

Present <strong>and</strong> Correct<br />

Manufacturer<br />

Present <strong>and</strong> Correct<br />

Complete Crane Functional <strong>and</strong> Operational Testing Crane Functions <strong>and</strong> Operation Through<br />

Full Range


Supplementary Element<br />

Crane Specific Requirements<br />

Basic Data Crane Location Canal Street Depot<br />

Tools Sheave Gauge<br />

<strong>Examination</strong> Areas<br />

Crane Description Miracle XM50<br />

Crane Identification Serial No. 123456<br />

Safe Working Load 50 tonne<br />

Crane Owner Krafty Krane Hire<br />

Authority/Permit to Work N/A<br />

Dial Test Indicator<br />

Area Element Feature<br />

Jib (Strut) N/A<br />

Jib (Telescopic) Structural Integrity Use inspection diagram on page 1221 <strong>of</strong> manual<br />

Wear pads Maximum wear 8.5 mm<br />

Jib (Fly) Structural Integrity Use inspection diagram on page 1228 <strong>of</strong> manual<br />

Sheaves Upper cathead sheave Bearing play on limits at last TE<br />

Ropes (Running<br />

<strong>and</strong> Static)<br />

Hoist <strong>and</strong><br />

Luffing<br />

Mechanism<br />

Discard Criteria 23 mm dia. Lang Lay – 2 broken wires over a<br />

length <strong>of</strong> 6 diameters (138 mm) <strong>and</strong> 4 broken wires<br />

over a length <strong>of</strong> 30 diameters (690 mm)<br />

Hoist Winch Obtain <strong>and</strong> review latest oil sample report<br />

86<br />

Determine used portion <strong>of</strong> theoretical life (manual<br />

page 1237)<br />

Hook Block Hook opening distortion Check opening against initial measurements<br />

marked on hook. Limit = 10% <strong>of</strong> initial.<br />

Slew<br />

Mechanism<br />

Thread corrosion <strong>and</strong> wear Examine as specified in Miracle Service Bulletin<br />

No. 09/32<br />

Bearing play Bearing clearance limit 2.0 mm. Check using<br />

procedure on 1019 <strong>of</strong> manual<br />

Slew ring bolts Obtain evidence <strong>of</strong> bolt torque check<br />

Lubrication Ensure evidence <strong>of</strong> correct lubrication (lack <strong>of</strong><br />

lubrication at last TE)


Structures Slew section structural integrity Use inspection diagram on page 1219 & 1220 <strong>of</strong><br />

manual<br />

Counterweight Structural Integrity NDT <strong>of</strong> attachment lugs as specified in Service<br />

Bulletin 08/04<br />

Chassis<br />

Outriggers<br />

Running Gear<br />

(Wheeled <strong>and</strong><br />

Tracked)<br />

Running Gear<br />

(Road Going)<br />

Super Structure<br />

Operation<br />

RCI<br />

RCL<br />

SWL<br />

Manufacturer’s<br />

Plate<br />

Structural Integrity Use inspection diagram on page 1216 <strong>of</strong> manual<br />

Structural Integrity Use inspection diagram on page 1217 <strong>of</strong> manual<br />

Hose protection See Service Bulletin 08/42<br />

N/A<br />

Wheel rim integrity Use inspection procedure on page 1231 <strong>of</strong> manual<br />

Brake system Use inspection procedure on page 1277 <strong>of</strong> manual<br />

No additions to generic<br />

requirements<br />

No additions to generic<br />

requirements<br />

Boom angle sensor See Service Bulletin 08/36<br />

Over lower limit See Service Bulletin 07/38<br />

No additions to generic<br />

requirements<br />

No additions to generic<br />

requirements<br />

Complete Crane No additions to generic<br />

requirements<br />

87


Annex 4 – Sample Document Covering <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong><br />

<strong>Examination</strong> Issues for <strong>Mobile</strong> Crane Users<br />

The effective maintenance <strong>and</strong> thorough examination <strong>of</strong> mobile cranes on<br />

construction site depends <strong>of</strong> a significant degree <strong>of</strong> cooperation between the mobile<br />

crane supplier/owner <strong>and</strong> the Principal Contractor. <strong>Mobile</strong> crane users (Principal<br />

Contractors) are frequently unaware <strong>of</strong> the part they have to play <strong>and</strong> the intention <strong>of</strong><br />

this document is to provide mobile crane suppliers/owners with a means <strong>of</strong> making<br />

users aware <strong>of</strong> their responsibilities <strong>and</strong> the need for effective cooperation.<br />

A5.1.0 Introduction<br />

An important part <strong>of</strong> the safe use <strong>of</strong> mobile cranes on construction sites is ensuring<br />

that mobile cranes are effectively maintained <strong>and</strong> subject to thorough examination at<br />

the appropriate intervals. This is normally undertaken by the mobile crane owner <strong>and</strong><br />

it is essential that mobile crane users fully appreciate the need to allocate sufficient<br />

time in the construction programme to allow these tasks to be carried out effectively.<br />

This document identifies the maintenance <strong>and</strong> thorough examination issues that<br />

must be agreed between the mobile crane owner <strong>and</strong> user before a mobile crane<br />

arrives on site.<br />

A5.2.0 Responsibility for <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

Both the Provision <strong>and</strong> Use <strong>of</strong> Work Equipment Regulations 1998 (PUWER) <strong>and</strong> the<br />

Lifting Operations <strong>and</strong> Lifting Equipment Regulations 1998 (LOLER) are very clear<br />

that the responsibility for ensuring that the maintenance <strong>and</strong> thorough examination <strong>of</strong><br />

mobile cranes is carried out, lies with the user <strong>of</strong> the mobile crane. In the case <strong>of</strong> a<br />

hired-in mobile crane the actual undertaking <strong>of</strong> maintenance or thorough examination<br />

is <strong>of</strong>ten delegated to the crane owner by the user. The user however, retains the<br />

legal responsibility for ensuring that both maintenance, including the rectification <strong>of</strong><br />

defects, <strong>and</strong> thorough examinations are carried out.<br />

A5.3.0 Downtime During <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

The main purpose for a mobile crane being on site is to carry out lifting operations as<br />

part <strong>of</strong> the construction process. Site managers are underst<strong>and</strong>ably reluctant to stop<br />

the crane whilst maintenance or thorough examination is carried out. If maintenance<br />

or thorough examination downtime is not scheduled into the construction programme<br />

it is pushed to the back <strong>of</strong> the queue <strong>and</strong> ends up being carried out hurriedly in<br />

unsafe conditions such as poor light.<br />

It is therefore essential that mobile crane users underst<strong>and</strong> that both maintenance<br />

<strong>and</strong> thorough examination are a legal requirement <strong>and</strong> that adequate downtime must<br />

be built into the site programme. <strong>Mobile</strong> crane owners should inform those hiring their<br />

cranes <strong>of</strong> the frequency <strong>and</strong> expected time required for maintenance <strong>and</strong> thorough<br />

examination at the planning stage, well before the crane arrives on site.<br />

Construction projects in built up areas <strong>of</strong>ten have environmental restrictions imposed<br />

on them which severely limit working time at week ends <strong>and</strong> such restrictions must<br />

be taken into account when planning maintenance <strong>and</strong> thorough examinations.<br />

A5.4.0 Lines <strong>of</strong> Communication<br />

It is essential that effective lines <strong>of</strong> communication are established between the user<br />

<strong>and</strong> those planning <strong>and</strong> carrying out both maintenance <strong>and</strong> thorough examination <strong>of</strong><br />

mobile cranes. This will avoid much frustration <strong>and</strong> misunderst<strong>and</strong>ing on both sides.<br />

88


A5.5.0 Availability <strong>of</strong> Operators<br />

<strong>Maintenance</strong> <strong>and</strong> thorough examination will require the crane to be operated from the<br />

control cab whilst maintenance personnel are carrying out their tasks or the<br />

competent person is examining other parts <strong>of</strong> the crane. Arrangements must be<br />

made to ensure that an operator is available on such occasions.<br />

A5.6.0 <strong>Thorough</strong> <strong>Examination</strong> Area<br />

The area in which any maintenance or thorough examination is being carried out<br />

should be <strong>of</strong> adequate size <strong>and</strong> cordoned <strong>of</strong>f to prevent access by persons not<br />

directly involved in these tasks.<br />

A5.7.0 Test Area<br />

Careful consideration should be given to the condition <strong>of</strong> any area where tests are to<br />

be conducted. The recommendations provided in the operating instructions for the<br />

crane relate to operations within the rated capacity <strong>and</strong> more stringent requirements<br />

apply when loads are being applied for the purpose <strong>of</strong> testing.<br />

The ground should be level, well consolidated <strong>and</strong> capable <strong>of</strong> withst<strong>and</strong>ing the loads<br />

applied to it. There should be no hidden dangers such as cable ducts, drains, pipes,<br />

back-filled areas, cellars or other subterranean weaknesses. <strong>Cranes</strong> should not be<br />

tested in the vicinity <strong>of</strong> overhead power lines.<br />

The test site should be <strong>of</strong> sufficient size with unrestricted overhead clearance to allow<br />

the unobstructed movement <strong>of</strong> the crane <strong>and</strong> load throughout its test movement, for<br />

example slewing, derricking <strong>and</strong> travelling.<br />

It is preferable that tests are not conducted over high risk areas, for example a public<br />

highway, railway, occupied buildings or in the flight path <strong>of</strong> airports. If due to the<br />

requirements <strong>of</strong> usage this is unavoidable, arrangements should be made with the<br />

appropriate authorities.<br />

If load testing is being carried it must be borne in mind that the crane might not<br />

withst<strong>and</strong> the loading. All personnel not essential to the test should be kept away<br />

from the area. The test area should be cordoned <strong>of</strong>f <strong>and</strong> notices posted prohibiting<br />

unauthorized entry. The site adjacent to the test area should be clear <strong>of</strong> plant <strong>and</strong><br />

property which could inhibit the test.<br />

A5.8.0 Availability <strong>of</strong> Site Facilities<br />

Arrangements should be made to ensure that site management, safety <strong>and</strong> welfare<br />

facilities are available to any personnel carrying out maintenance or through<br />

examination both within <strong>and</strong> outside normal working hours. Facilities should include<br />

<strong>of</strong>fice space for the review <strong>of</strong> documentation.<br />

A5.9.0 Access For Deliveries<br />

<strong>Maintenance</strong> operations, particularly the rectification <strong>of</strong> breakdowns <strong>of</strong>ten require<br />

spare parts to be delivered to site. Care must be taken to ensure that there is<br />

adequate access for delivery <strong>and</strong> that adequate acceptance procedures are in place<br />

to ensure that the parts are available when required by maintenance personnel <strong>and</strong><br />

are not lost on site.<br />

A5.10.0 Lone Working<br />

Lone working should be avoided at all times by suitable liaison with the person in<br />

control <strong>of</strong> the site to ensure that site personnel are always in attendance.<br />

89


The planning process for work at height on mobile cranes should take into account<br />

the particular hazards <strong>of</strong> lone working <strong>and</strong> thorough examination at height by lone<br />

workers should not be undertaken.<br />

A5.11.0 Work at Height<br />

Some maintenance <strong>and</strong> thorough examination activities on mobile cranes may<br />

require maintenance personnel or competent persons to work at height outside edge<br />

protected areas on the mobile crane structure. The Work at Height Regulations 2005<br />

set out a hierarchy <strong>of</strong> fall protection measures to be taken when planning work at<br />

height.<br />

This means that those planning work at height on mobile cranes should:-<br />

� Avoid work at height wherever possible <strong>and</strong> actively seek solutions to<br />

facilitate this;<br />

� If this is not possible, use “collective” means <strong>of</strong> protection such as guardrails;<br />

� If this is not possible, use “personal” means <strong>of</strong> prevention such as work<br />

restraint;<br />

� If this is not possible, use a personal fall protection system such as a work<br />

positioning system or fall arrest system;<br />

� Additionally provide training <strong>and</strong> instruction or take other measures to prevent<br />

any person falling a distance liable to cause personal injury.<br />

Where a risk assessment indicates that a personal fall protection system is required<br />

a work positioning system should always be used in preference to a fall arrest<br />

system. Where the use <strong>of</strong> fall arrest personal fall protection systems are unavoidable<br />

there will be a risk <strong>of</strong> the wearer being left suspended following a fall <strong>and</strong><br />

arrangements must be made to ensure that they can be rescued in a safe <strong>and</strong> timely<br />

manner.<br />

A5.12.0 Isolation <strong>of</strong> Systems During <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong> <strong>Examination</strong><br />

To avoid the risk <strong>of</strong> trapping, crushing, shearing or electrocution during the<br />

maintenance or thorough examination <strong>of</strong> mechanisms on mobile cranes, all systems<br />

should be provided with a means <strong>of</strong> isolation. Where a system requires power for<br />

maintenance or thorough examination, a safe system <strong>of</strong> work should be put in place<br />

to mitigate the risks <strong>of</strong> trapping. Such a safe system <strong>of</strong> work may well involve a<br />

“permit to work” <strong>and</strong> adequate communication between the crane operator <strong>and</strong> other<br />

members <strong>of</strong> the maintenance or thorough examination team.<br />

90


A5.13.0 Communication Equipment<br />

Personnel carrying out maintenance or thorough examinations should be provided<br />

with an adequate means <strong>of</strong> communication, <strong>of</strong>ten h<strong>and</strong> held portable radios, to<br />

ensure that all members <strong>of</strong> the thorough examination team can communicate<br />

effectively with each other, the mobile crane operator <strong>and</strong> personnel on the ground.<br />

NOTE: Additional advice on radio communications is given in the CPA Technical Information<br />

Note TIN 017 - Radio Communication for Lifting Operations.<br />

A5.14.0 Additional Information<br />

Provision & Use <strong>of</strong> Work Equipment Regulations 1998/SI2306<br />

L22 Safe use <strong>of</strong> work equipment, HSE Books.<br />

Lifting Operations & Lifting Equipment Regulations 1998/SI2307<br />

L113 Safe use <strong>of</strong> lifting equipment, HSE Books.<br />

BS 7121-1:2006, Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 1: General<br />

BS 7121-2:2003, Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 2: <strong>Inspection</strong>,<br />

testing <strong>and</strong> examination<br />

BS 7121-3:2000, Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 3: <strong>Mobile</strong> cranes<br />

91


Annex 5 – Typical In-service <strong>Maintenance</strong> Schedule<br />

92


Annex 6 - Daily Pre-use Checks <strong>and</strong> Weekly <strong>Inspection</strong>s<br />

The daily checks that must be carried out at the start <strong>of</strong> every shift should include everything in the following list. Weekly inspections must be made in addition to<br />

the daily checks. Additional checks may be required by the mobile crane owner, based on advice given to them by the manufacturer <strong>of</strong> the crane.<br />

93


Annex 7 – Example <strong>of</strong> a Lifting Accessory Register<br />

Vehicle OY06 0YS<br />

Employing<br />

Organisation<br />

Lifting Accessory Register<br />

BB Crane Hire<br />

Description SWL Weight<br />

Appointed<br />

Person<br />

94<br />

Ident.<br />

No.<br />

F Bloggs<br />

Location<br />

Contact<br />

Telephone<br />

No<br />

Date <strong>of</strong> Last<br />

<strong>Thorough</strong><br />

<strong>Examination</strong><br />

0161 953<br />

8765<br />

Date <strong>of</strong> Next<br />

<strong>Thorough</strong><br />

<strong>Examination</strong><br />

1. Violet web sling 2m long with choker hooks 1400 kg 4 kg W22228 Storage Locker 23.01.09 23.07.10<br />

3. 2 leg 8mm chain sling 2 m leg length 2000 kg 7.5 kg K26977 Storage Locker 19.12.09 19.05.10<br />

4. 4 leg 10mm chain sling 2.5m leg length 4750 kg 31 kg K17396 Storage Locker 19.12.09 19.05.10<br />

5. 6 tonne D shackle 6000 kg 4.5 kg B1289 Storage Locker 19.12.09 19.05.10


Annex 8 – Example <strong>of</strong> the Use <strong>of</strong> Key Performance Indicators for <strong>Maintenance</strong><br />

Basic Data<br />

KPI Jan Feb Mar Apr May June Jul Aug Sept Oct Nov Dec<br />

No. <strong>of</strong> <strong>Cranes</strong> in the<br />

fleet 70 70 70 72 68 68 69 69 70 70 70 70<br />

Spare Part<br />

Purchases X £1k 36 34 32 33 39 40 30 34 36 33 28 28<br />

No. <strong>of</strong> Tradesmen 9 9 9 10 10 10 9 9 9 9 9 9<br />

Basic Hours 1440 1440 1440 1600 1600 1600 1440 1440 1440 1440 1440 1440<br />

Overtime Hours 200 220 210 200 230 240 220 210 220 215 215 150<br />

Total Hours 1640 1660 1650 1800 1830 1840 1660 1650 1660 1655 1655 1590<br />

PMs Completed 40 46 43 42 40 36 48 40 36 40 40 40<br />

PDIs Completed 9 10 9 10 9 10 8 9 10 9 10 8<br />

No. <strong>of</strong> Breakdown<br />

Visits 10 8 10 12 10 8 7 8 6 4 7 6<br />

Fleet Utilisation 86 89 93 89 97 82 81 86 83 81 83 71<br />

Hours<br />

£ x 1000<br />

2000<br />

1500<br />

1000<br />

500<br />

0<br />

Basic <strong>and</strong> Overtime Hours<br />

Jan Feb Mar Apr May June Jul Aug Sept Oct Nov Dec<br />

Overtime Hours 200 220 210 200 230 240 220 210 220 215 215 150<br />

Basic Hours 1440 1440 1440 1600 1600 1600 1440 1440 1440 1440 1440 1440<br />

95<br />

Month<br />

<strong>Maintenance</strong> Spares Expenditure<br />

50<br />

40<br />

30<br />

20<br />

10<br />

0<br />

Jan Feb Mar Apr May June Jul Aug Sept Oct Nov Dec<br />

Spare Part Purchases X £1000 36 34 32 33 39 40 30 34 36 33 28 28<br />

Month


Number<br />

Percentage<br />

Number <strong>of</strong> PDIs, PMs & Breakdowns Completed<br />

80<br />

60<br />

40<br />

20<br />

0<br />

Number <strong>of</strong> PDIs Completed 9 10 9 10 9 10 8 9 10 9 10 8<br />

Number <strong>of</strong> Breakdow n Visits 10 8 10 12 10 8 7 8 6 4 7 6<br />

Number <strong>of</strong> PMs Competed 40 46 43 42 40 36 48 40 36 40 40 40<br />

120<br />

100<br />

80<br />

60<br />

40<br />

20<br />

0<br />

Jan Feb Mar Apr May June Jul Aug Sept Oct Nov Dec<br />

Fleet Utilisation<br />

96<br />

Month<br />

Month<br />

1 2 3 4 5 6 7 8 9 10 11 12<br />

Fleet Utilisation 86 89 93 89 97 82 81 86 83 81 83 71


Annex 9 – Example <strong>of</strong> the Use <strong>of</strong> Key Performance Indicators for <strong>Thorough</strong><br />

<strong>Examination</strong><br />

Basic Data<br />

KPI Jan Feb Mar Apr May June Jul Aug Sept Oct Nov Dec<br />

No. <strong>of</strong> TEs Completed 9 10 9 10 9 10 8 9 10 9 10 8<br />

No. <strong>of</strong> Immediate Defects 1 2 1 2 1 1 0 1 0 2 2 2<br />

No. <strong>of</strong> Timed Defects 4 3 0 2 1 3 1 1 0 3 3 3<br />

% Immediate Defects 11 20 11 20 11 10 0 11 0 22 20 25<br />

% Timed Defects 44 30 0 20 11 30 13 11 0 33 30 38<br />

No. <strong>of</strong> hire days lost due<br />

to Immediate Defects 3 4 1 7 1 2 0 2 0 3 1 2<br />

Access denied to crane<br />

for TE or <strong>Maintenance</strong> 2 1 1 3 1 2 1 0 0 1 3 2<br />

Number<br />

Number<br />

Number <strong>of</strong> <strong>Thorough</strong> <strong>Examination</strong>s Completed<br />

15<br />

10<br />

5<br />

0<br />

1 2 3 4 5 6 7 8 9 10 11<br />

Number <strong>of</strong> TEs Completed 9 10 9 10 9 10 8 9 10 9 10<br />

Number <strong>of</strong> Immediate Defects 1 2 1 2 1 1 0 1 0 2 2<br />

Number <strong>of</strong> Timed Defects 4 3 0 2 1 3 1 1 0 3 3<br />

Access to crane denied for <strong>Thorough</strong> <strong>Examination</strong> or<br />

<strong>Maintenance</strong> at scheduled visit agreed with site<br />

4<br />

3<br />

2<br />

1<br />

0<br />

Jan Feb Mar Apr May June Jul Aug Sept Oct Nov Dec<br />

Number <strong>of</strong> Denials 2 1 1 3 1 2 1 0 0 1 3 2<br />

97<br />

Month


Annex 10 - Supplementary Reports <strong>and</strong> Tests Supporting <strong>Thorough</strong><br />

<strong>Examination</strong><br />

A10.1 Report <strong>of</strong> Load Test Following Major Repair<br />

This test would normally be completed shortly after an major repair <strong>of</strong> a mobile crane<br />

at a new location to confirm the structural integrity <strong>of</strong> the crane following repair <strong>and</strong> to<br />

detect any weaknesses. The magnitude <strong>of</strong> the test load should be as specified by the<br />

crane manufacturer.<br />

The report should include:-<br />

� Date the test <strong>and</strong> subsequent examination was completed;<br />

� The configuration <strong>of</strong> the crane at time <strong>of</strong> test;<br />

� The unique serial number or identifying mark <strong>of</strong> the crane;<br />

� Test weights <strong>and</strong> radii tested;<br />

� Details <strong>of</strong> any defects or deformation observed.<br />

A10.2 RCI/RCL Calibration <strong>and</strong> Functional Test Report<br />

This is a report <strong>of</strong> the results <strong>of</strong> a functional <strong>and</strong> calibration check on the rated<br />

capacity system. The report should include confirmation <strong>of</strong> correct function <strong>of</strong>:-<br />

� Visual displays <strong>and</strong> read outs;<br />

� Warning lights advising <strong>of</strong> the approach to, <strong>and</strong> reaching <strong>of</strong>, an overload<br />

condition (hoist <strong>and</strong> moment systems);<br />

� Audible alarms internal <strong>and</strong> external to the cab;<br />

� Prevention <strong>of</strong> dangerous crane movements when an overload condition has<br />

been reached;<br />

� Override keys (i.e. spring loaded);<br />

� Self test on first power up.<br />

Calibration <strong>of</strong> the unit would normally include:-<br />

� Zero load calibration;<br />

� Calibration completed with a test load <strong>of</strong> a known value close to the maximum<br />

lifting capacity <strong>of</strong> the crane;<br />

� Radius calibration at minimum <strong>and</strong> maximum radius;<br />

� Pre-Overload <strong>and</strong> Overload warning.<br />

A10.3 Anemometer Calibration <strong>and</strong> Functional Test Report<br />

This is a report recording the results <strong>of</strong> a functional <strong>and</strong> calibration check <strong>of</strong> an<br />

anemometer. The report should include confirmation <strong>of</strong>:-<br />

� Suitable location <strong>and</strong> function <strong>of</strong> the wind speed sensor;<br />

� Function <strong>and</strong> calibration check <strong>of</strong> the indicating system;<br />

� Function <strong>and</strong> setting <strong>of</strong> any warning indicators or alarms;<br />

� The make, serial number <strong>and</strong> calibration details <strong>of</strong> the h<strong>and</strong> held<br />

anemometer, or other test device, used to verify the calibration <strong>of</strong><br />

anemometer mounted on the crane.<br />

98


The appointed person responsible for the in-service lifting operations should specify<br />

the setting values for the anemometer warning indicators <strong>and</strong> alarms.<br />

A10.4 Test Report <strong>of</strong> NDT <strong>of</strong> Individual Components<br />

Non-destructive testing may be requested by the competent person to supplement<br />

any visual examination. Where requested, such information should be made available<br />

to the competent person. The report should include:-<br />

� Date the tests were completed;<br />

� Name, qualifications <strong>and</strong> position <strong>of</strong> the person completing the tests;<br />

� Serial number or identifying mark <strong>of</strong> the components examined;<br />

� Details <strong>of</strong> the test method employed <strong>and</strong> reference to appropriate st<strong>and</strong>ards;<br />

� Calibration details <strong>of</strong> any test equipment used;<br />

� Results <strong>of</strong> the examination.<br />

A10.5 Slew Ring Clearances <strong>and</strong> Condition Report<br />

This is a report detailing the clearances measured at the slew ring bearing. Slew ring<br />

bearing clearance measurements are most effectively made in a workshop<br />

environment. The frequency <strong>of</strong> examination should be in line with the manufacturer’s<br />

recommendations, at an increased frequency if the crane has been subjected to<br />

arduous service conditions or at the request <strong>of</strong> the competent person completing<br />

thorough examination.<br />

During the test an axial load is typically applied to the ring using hydraulic jacks or an<br />

overhead crane <strong>and</strong> the clearances/movement <strong>of</strong> the bearing measured with dial<br />

indicator gauges. The measurements should be taken at various positions around the<br />

ring with the bearing indexed during the test to a minimum <strong>of</strong> four geometric positions.<br />

The report should specify the maximum clearance allowed by the manufacturer for the<br />

specific slew ring type <strong>and</strong> model. It is recommended that results <strong>of</strong> previous<br />

examinations be recorded on the same report in order that an assessment can be<br />

made as to the rate that clearances are increasing.<br />

A basic assessment as to the condition <strong>of</strong> bearing faces <strong>and</strong> rolling elements can<br />

<strong>of</strong>ten be made by rotating the bearing whilst under a vertical axial load. The slew ring<br />

should where possible be rotated by h<strong>and</strong> rather than via the slew ring motor. Any<br />

tight spots, grumbling or clicking <strong>of</strong> the bearing should be noted <strong>and</strong> investigated by<br />

stripping down <strong>of</strong> the bearing assembly for close visual examination.<br />

The condition <strong>and</strong> function <strong>of</strong> greasing systems, grease lines, nipples <strong>and</strong> lip seals<br />

should be ascertained.<br />

An indication <strong>of</strong> slew ring bearing clearance may also be obtained on a mobile crane<br />

without disassembly. In this case measurements should be taken using a dial test<br />

indicator (DTI) mounted on the centreline <strong>of</strong> the bearing track. The DTI should be<br />

zeroed with no load on the hood (back moment condition). A load should then be lifted<br />

at such a radius that a forward moment condition is created <strong>and</strong> the bearing moves to<br />

the other extent <strong>of</strong> its play. The process can then be repeated with the crane slewed<br />

through 45° increments.<br />

Measurement <strong>of</strong> slew ring bearing play on an assembled crane will not give result that<br />

is as accurate as axial loading in workshop conditions, but will give a good indication<br />

<strong>of</strong> excessive wear <strong>and</strong> the need for any corrective action.<br />

The report should include:-<br />

� Date the examination was completed;<br />

� Unique serial number or identifying mark <strong>of</strong> the slew ring;<br />

99


� Measurements taken <strong>and</strong> relative geometric index position;<br />

� Manufacturers specifications;<br />

� Previous recorded values;<br />

� Assessment as to the condition <strong>of</strong> the bearing faces <strong>and</strong> rolling elements;<br />

� Confirmation as to the function <strong>of</strong> the grease nipple <strong>and</strong> systems.<br />

It is good practice to measure the slew bearing clearance on new cranes at first<br />

erection to provide a reference value against which all subsequent measurements can<br />

be assessed.<br />

A10.6 Hoist Brake Test <strong>and</strong> <strong>Examination</strong><br />

This is a test <strong>of</strong> the operational efficiency <strong>of</strong> the hoist brakes. This test may also be<br />

completed following major overhaul <strong>of</strong> the braking system, replacement <strong>of</strong> brake<br />

shoes or pads, or in the event that the brake has failed to arrest or hold a load.<br />

The operational test should include:-<br />

� Dynamic testing to confirm that the brake can bring to rest a moving load<br />

being lifted or lowered at the normal maximum operational speed;<br />

� Dynamic testing to confirm that the brake can bring to rest a moving load<br />

being lifted or lowered at the normal maximum operational speed following<br />

operation <strong>of</strong> the emergency stop;<br />

� Static testing to confirm that the brake can hold without slippage a static load.<br />

A10.7 <strong>Maintenance</strong> Records<br />

The competent person may request a copy <strong>of</strong> the maintenance log/reports for the<br />

crane. This information may be provided as individual records or in summary form.<br />

A10.8 Hydraulic System<br />

The competent person may request reports <strong>and</strong> tests on various aspects <strong>of</strong> the<br />

crane’s hydraulic system including:-<br />

� Hydraulic oil sampling <strong>and</strong> analysis for contaminants to aid assessment <strong>of</strong><br />

component wear;<br />

� Cylinder lock valve holding capability;<br />

� Accumulator integrity;<br />

� Filter replacement intervals;<br />

� Pressure testing <strong>of</strong> components.<br />

A10.9 Boom extension system<br />

The boom extension <strong>of</strong> most mobile cranes is an enclosed system which will require<br />

full or partial dismantling, at intervals prescribed by the competent person, in order<br />

that components such as telescoping <strong>and</strong> retracting ropes, end fastenings <strong>and</strong><br />

sheaves may be examined for damage, wear <strong>and</strong> deterioration. A report <strong>of</strong> condition<br />

<strong>and</strong> any items replaced should be provided to the competent person.<br />

In setting out the scope <strong>of</strong> inspection <strong>of</strong> the boom extension system the competent<br />

person should indicate whether they wish to be present at the inspection.<br />

100


A10.10 Wire ropes<br />

The examination <strong>of</strong> wire ropes as part <strong>of</strong> the thorough examination <strong>of</strong> a mobile crane<br />

should be based on the principles <strong>and</strong> requirements set out in BS ISO 4309:2004,<br />

<strong>Cranes</strong>. Wire ropes. Care, maintenance, installation, examination <strong>and</strong> discard<br />

This document stresses the importance <strong>of</strong> examining critical areas <strong>of</strong> the rope such<br />

as:-<br />

� The termination points <strong>of</strong> both moving <strong>and</strong> stationary ropes;<br />

� That part <strong>of</strong> the rope which passes through the block or over sheaves;<br />

� In the case <strong>of</strong> cranes performing a repetitive operation, any part <strong>of</strong> the rope<br />

which lies over sheave(s) while the crane is in a loaded condition;<br />

� That part <strong>of</strong> the rope which lies over a compensating sheave;<br />

� Any part <strong>of</strong> the rope which may be subject to abrasion by external features.<br />

A10.11 Electrical control system<br />

Many mobile cranes are fitted with sophisticated microprocessor based control<br />

systems with inbuilt diagnostic capability including detailed test programs. The<br />

competent person may require these test programs to be run <strong>and</strong> the results made<br />

available for his inspection.<br />

A10.12 Slew brake<br />

This is a test <strong>of</strong> the operational efficiency <strong>of</strong> the slew brake. This test may also be<br />

completed following major overhaul <strong>of</strong> the braking system, replacement <strong>of</strong> brake<br />

shoes or pads, or in the event that the brake has failed to arrest or hold a load. The<br />

operational test should include dynamic testing to confirm that the brake can bring to<br />

rest a moving load being slewed at the normal maximum operational speed.<br />

A10.13 Sheaves<br />

Sheaves should be checked frequently to ensure that they rotate freely <strong>and</strong> that nay<br />

play in the bearings is within limits. The radius at the bottom <strong>of</strong> the sheave groove<br />

should be checked with a set <strong>of</strong> sheave gauges to ensure that it is within limits. These<br />

are normally no smaller that nominal rope diameter + 5% <strong>and</strong> no greater than nominal<br />

rope diameter +15%.<br />

A10.14 Chassis<br />

It is important that the chassis is prepared for structural thorough examination by<br />

pressure washing to remove dirt, debris <strong>and</strong> grease so that any defects can be clearly<br />

identified.<br />

A10.15 ATEX equipment (spark arrestor)<br />

Spark arresters should be tested by running the engine in a safe environment <strong>and</strong><br />

examining the exhaust discharge in darkness for any sparks. If the engine is being run<br />

in an enclosed space adequate precautions must be taken to avoid the effects <strong>of</strong><br />

exhaust fumes, in particular carbon monoxide poisoning.<br />

A10.16 Hoist/luffing winch<br />

Hoist <strong>and</strong> luffing winches are designed on the basis <strong>of</strong> a theoretical service life taking<br />

into account a number <strong>of</strong> factors including the power unit group, load spectrum <strong>and</strong><br />

collective service factor. This theoretical service is not the same as the real (actual)<br />

service lift. At least every year an assessment <strong>of</strong> the proportion <strong>of</strong> the theoretical<br />

service lift left must be made to determine when the next major overhaul <strong>of</strong> each<br />

101


winch must be carried out. This is carried out using the information supplied by the<br />

crane manufacturer, together with the effective operating hours for the winch <strong>and</strong> an<br />

assessment <strong>of</strong> load spectrum for the winch over the period.<br />

A10.17 Hook blocks<br />

The inspection <strong>of</strong> hook blocks should assess the general condition <strong>of</strong> the assembly<br />

<strong>and</strong> in particular the condition <strong>of</strong> bearing <strong>and</strong> fasteners. The mouth <strong>of</strong> the load hook<br />

should be checked for deformation by measuring between the marked datum points<br />

<strong>and</strong> comparing the value obtained with the original dimensions marked on the hook<br />

data plate. The increase should not exceed the value specified by the manufacturer<br />

(normally 10%)<br />

A10.18 Stowage for transport<br />

This is a functional test <strong>and</strong> examination to confirm that the cranes superstructure can<br />

be stowed for transport in accordance with the manufacturer’s instructions. Specific<br />

checks should be made to ensure that;<br />

� The boom rests correctly in the transport position<br />

� The slew locking system can be applied <strong>and</strong> is effective<br />

� Counterweights either attached to the slewing structure or chassis are secure<br />

� Fly jib, where fitted, is secure<br />

102


Annex 11 – Qualifications <strong>and</strong> Assessment <strong>of</strong> <strong>Maintenance</strong> <strong>and</strong> <strong>Thorough</strong><br />

<strong>Examination</strong> Personnel<br />

<strong>Maintenance</strong><br />

Manager<br />

Role Qualifications (minimum)<br />

Depot/Workshop<br />

Mechanics<br />

Field Service<br />

<strong>Maintenance</strong><br />

Personnel<br />

C&G/NVQ Level 3, Introduction<br />

to the Management <strong>of</strong> <strong>Thorough</strong><br />

<strong>Examination</strong>, The Management<br />

<strong>of</strong> <strong>Mobile</strong> <strong>Cranes</strong><br />

C&G/NVQ Level 2 in Plant<br />

<strong>Maintenance</strong>, CPCS<br />

Slinger/Signaller<br />

C&G/NVQ Level 2 in Plant<br />

<strong>Maintenance</strong> <strong>and</strong> NVQ Level 3<br />

in Plant <strong>Maintenance</strong>, CPCS<br />

Slinger/Signaller<br />

103<br />

Additional<br />

Competencies<br />

Product specific<br />

knowledge<br />

Product specific<br />

knowledge,<br />

Introduction to the<br />

<strong>Thorough</strong><br />

<strong>Examination</strong><br />

Product specific<br />

knowledge<br />

Operator CPCS <strong>Mobile</strong> Crane (S/NVQ) Product specific<br />

knowledge including<br />

operator<br />

maintenance<br />

activities<br />

Competent<br />

Person<br />

(thorough<br />

examination)<br />

a) Engineering Technician as<br />

defined by the Engineering<br />

Council or equivalent (e.g.<br />

appropriate ONC with relevant<br />

experience) having a minimum<br />

<strong>of</strong> 5 years experience within a<br />

relevant discipline <strong>of</strong> which at<br />

least one year shall have been<br />

spent working within an<br />

engineering discipline related to<br />

lifting equipment or<br />

b) Person trained in a relevant<br />

engineering discipline with a<br />

recognised <strong>and</strong> documented<br />

engineering apprenticeship (in<br />

lieu <strong>of</strong> an academic qualification)<br />

with a minimum <strong>of</strong> 5 years<br />

experience within a relevant<br />

discipline <strong>of</strong> which at least one<br />

year shall have been spent<br />

working within an engineering<br />

discipline related to lifting<br />

equipment or<br />

c) Introduction <strong>of</strong> <strong>Thorough</strong><br />

<strong>Examination</strong> or SAFed<br />

equivalent<br />

Product specific<br />

knowledge<br />

Location <strong>of</strong><br />

Additional<br />

Competencies<br />

Available from<br />

crane <strong>and</strong><br />

component<br />

manufacturers<br />

Available from<br />

manufacturers<br />

<strong>and</strong> others<br />

including NCC<br />

Available from<br />

manufacturers<br />

<strong>and</strong> others.<br />

Available from<br />

manufacturer<br />

<strong>and</strong> others<br />

Available from<br />

manufacturer<br />

<strong>and</strong> others<br />

including mobile<br />

crane owner<br />

NOTE: Employers must determine competence <strong>of</strong> each individual person, both existing<br />

employees <strong>and</strong> new entrants, based on the attributes listed above together with academic<br />

qualifications. A shortfall on attainment level does not preclude employment in this role but such<br />

shortfalls must be addressed before the person is allowed to carry out the role.


Annex 12 – “Grey” Imports<br />

This annex is based on guidance <strong>and</strong> advice given by the HSE to their inspectors on<br />

the controversial issue <strong>of</strong> “grey import” machines coming from outside the EU. This<br />

advice is reproduced, (apart from a few changes to the clarify the meaning,) to help<br />

readers underst<strong>and</strong> the st<strong>and</strong>ards that the inspectors look for when inspecting any<br />

mobile cranes imported from outside the EEA (European Economic Area – EU States<br />

plus Norway, Icel<strong>and</strong> <strong>and</strong> Liechtenstein), in particular those that do not meet EU<br />

requirements.<br />

Introduction<br />

There is concern in the UK about the safety <strong>of</strong> machines manufactured <strong>and</strong> imported<br />

from outside the EU, that were not originally designed <strong>and</strong> constructed to meet<br />

European st<strong>and</strong>ards.<br />

These machines, some <strong>of</strong> which are mobile cranes, should meet the same essential<br />

health <strong>and</strong> safety requirements (EHSRs) as any other machine under the Supply <strong>of</strong><br />

Machinery (Safety) Regulations 2008 (SM(S)R).<br />

Under SM(S)R all new mobile cranes are presumed to comply with the EHSRs if they<br />

have been made to the European St<strong>and</strong>ard BS EN 13000 or equivalent st<strong>and</strong>ards,<br />

<strong>and</strong> are safe to use. The design <strong>and</strong> material specification for the machine has to be<br />

kept in a technical file that is normally held by the manufacturer, <strong>and</strong> is required by<br />

whoever carries out the conformity examination.<br />

In order to meet the st<strong>and</strong>ards <strong>of</strong> safety under SM(S)R, the Provision <strong>and</strong> Use <strong>of</strong><br />

Work Equipment Regulations 1998, <strong>and</strong> the Noise at Work Regulations 1989,<br />

machines must comply with the following requirements:<br />

(1) All mobile cranes should be supplied with operator <strong>and</strong> routine maintenance<br />

instructions in English. Operating instructions are needed for routine maintenance<br />

<strong>and</strong> all written directions in the cab must also be in English.<br />

(2) Controls must be appropriately marked to indicate their function <strong>and</strong> mode <strong>of</strong><br />

operation, <strong>and</strong> must be positioned, <strong>and</strong> protected so that the desired effect,<br />

where a risk is involved, cannot occur without intentional operation.<br />

(3) Any mobile crane that can lift loads in excess <strong>of</strong> one tonne must have a rated<br />

capacity indicator/limiter fitted to it, providing visual warning to the driver before<br />

the safe working load (SWL) is reached, with both visual <strong>and</strong> audible warning to<br />

the driver <strong>and</strong> anyone else in the vicinity <strong>of</strong> the machine, when the SWL is<br />

reached. The rated capacity limiter must prevent the crane from supporting a load<br />

outside the limits <strong>of</strong> the permitted radii, <strong>and</strong> outside the positions <strong>and</strong> loads<br />

shown <strong>and</strong>/or described on the rated capacity chart <strong>and</strong> current test certificate or<br />

the permissible working load <strong>of</strong> the ropes.<br />

(4) Any mobile crane must meet the noise levels laid down by the Outdoor Noise<br />

Directive 200/14/EC (as amended). A noise decal is also required by the Noise at<br />

Work Regulations 1989.<br />

There are also a large number <strong>of</strong> requirements in EN13000 such as stability,<br />

m<strong>and</strong>atory limiters <strong>and</strong> indicators, control systems, braking systems, guards, access,<br />

hydraulic, pneumatic <strong>and</strong> electrical systems, visibility, noise <strong>and</strong> lighting, which may<br />

well not be met by cranes imported from countries outside the EEA.<br />

Declaration <strong>of</strong> Conformity<br />

New mobile cranes supplied under SM(S)R are required to be CE marked, have a<br />

declaration <strong>of</strong> conformity, be supplied with instructions for use, <strong>and</strong> fitted with a range<br />

safety features. Grey imports may look similar to other machines but information on<br />

their construction, use <strong>and</strong> maintenance may not be made available by the<br />

manufacturer to others.<br />

104


A declaration <strong>of</strong> conformity is required to be supplied with the machine in accordance<br />

with SM(S)R, regulation 7.(2)(e). This does not have to be kept with the machine on<br />

site, but it should be retained by the purchaser.<br />

The declaration <strong>of</strong> conformity should refer to the relevant st<strong>and</strong>ards used in the<br />

construction <strong>of</strong> the mobile crane <strong>and</strong> be capable <strong>of</strong> being cross-referenced with other<br />

design information. It is <strong>of</strong> value because it may be used to compare design st<strong>and</strong>ards<br />

with the guidance given in BS EN 13000.<br />

The manufacturer does not have to use the European St<strong>and</strong>ards, whose use is<br />

voluntary, but may instead satisfy the relevant EHSRs.<br />

CE Mark<br />

The CE marking is required to be fixed to the mobile crane in accordance with<br />

SM(S)R, regulation 7.(2)(f).<br />

The lack <strong>of</strong> a CE marking, or an inappropriate CE mark, would indicate that the mobile<br />

crane had not been made to SM(S)R. It would not necessarily indicate that the mobile<br />

crane was unsafe but it increases the likelihood, <strong>and</strong> information may be required to<br />

justify any claim that the machine meets the EHSRs <strong>and</strong> is safe to use.<br />

Advice<br />

If a mobile crane is being purchased from outside the EU the purchaser will be treated<br />

as the importer <strong>and</strong> must take suitable steps to ensure that the crane meets the<br />

requirements <strong>of</strong> SM(S)R, regardless <strong>of</strong> the age <strong>of</strong> the machine. This will normally<br />

involve the purchaser engaging the services <strong>of</strong> a specialist to undertake the<br />

assessment <strong>of</strong> the build st<strong>and</strong>ard <strong>of</strong> the crane against the EHSRs <strong>and</strong> relevant<br />

European st<strong>and</strong>ards, identifying those areas which do not comply. Any non-compliant<br />

areas must be addressed before the crane is taken into use. Records <strong>of</strong> this<br />

assessment <strong>and</strong> any rectification must be kept.<br />

Upon completion the crane must be CE marked in accordance with SM(S)R <strong>and</strong> a<br />

Declaration <strong>of</strong> Conformity issued.<br />

105


Bibliography<br />

Legislation<br />

Health & Safety at Work etc Act 1974<br />

Management <strong>of</strong> Health & Safety at Work Regulations 1999/SI3242<br />

Workplace (Health, Safety & Welfare) Regulations 1992/SI3004<br />

Provision & Use <strong>of</strong> Work Equipment Regulations 1998/SI2306<br />

L22 Safe use <strong>of</strong> work equipment, HSE Books<br />

Lifting Operations & Lifting Equipment Regulations 1998/SI2307<br />

L113 Safe use <strong>of</strong> lifting equipment, HSE Books<br />

Personal Protective Equipment at Work Regulations 1992/SI2966<br />

Work at Height Regulations 2005/SI735.<br />

Supply <strong>of</strong> Machinery (Safety) Regulations 2008/SI1597<br />

The Construction (Design <strong>and</strong> Management) Regulations 2007/SI320<br />

The Reporting <strong>of</strong> Injuries, Diseases <strong>and</strong> Dangerous Occurrences Regulations<br />

1995/SI3163<br />

The Air Navigation Order 2000/SI1562<br />

St<strong>and</strong>ards<br />

BS 6166-3:1998, Lifting slings — Part 3: Guide to the selection <strong>and</strong> safe use <strong>of</strong> lifting<br />

slings for multi-purposes<br />

BS 7121-1:2006, Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 1: General<br />

BS 7121-2:2003, Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 2: <strong>Inspection</strong>, testing<br />

<strong>and</strong> examination<br />

BS 7121-3:2000, Code <strong>of</strong> practice for safe use <strong>of</strong> cranes — Part 3: <strong>Mobile</strong> cranes<br />

BS 7262:1990, Specification for automatic safe load indicators<br />

BS 7883:2005 - Code <strong>of</strong> practice for application <strong>and</strong> use <strong>of</strong> anchor devices<br />

conforming to BS EN 795.<br />

BS 8437:2005 - Code <strong>of</strong> practice for selection, use <strong>and</strong> maintenance <strong>of</strong> personal fall<br />

protection systems <strong>and</strong> equipment for use in the workplace.<br />

BS EN 795:1997 - Protection against falls from a height — Anchor devices —<br />

Requirements <strong>and</strong> testing<br />

BS EN 970:1997 - Non-destructive examination <strong>of</strong> fusion welds. Visual examination<br />

BS EN 12385-1:2002, Steel wire ropes — Safety — Part 1: General requirements<br />

BS EN 12385-2:2002, Steel wire ropes — Safety — Part 2: Definitions, designation<br />

<strong>and</strong> classification<br />

BS EN 12385-3:2004, Steel wire ropes — Safety — Part 3: Information for use <strong>and</strong><br />

maintenance<br />

106


BS EN 12385-4:2002, Steel wire ropes — Safety — Part 4: Str<strong>and</strong>ed ropes for<br />

general lifting applications<br />

BS EN 13411 Parts 1 – 6, Wire rope terminations<br />

BS EN 13557:2003, <strong>Cranes</strong> — Controls <strong>and</strong> control stations<br />

BS EN 13586:2004, <strong>Cranes</strong> — Access<br />

BS EN 14502-1:2005, <strong>Cranes</strong> — Equipment for the lifting <strong>of</strong> persons — Part 1:<br />

Suspended baskets<br />

BS ISO 4309:2004, <strong>Cranes</strong>. Wire ropes. Care, maintenance, installation, examination<br />

<strong>and</strong> discard<br />

BS EN ISO/IEC 17020:2004, General criteria for the operation <strong>of</strong> various types <strong>of</strong><br />

bodies performing inspection<br />

BS EN ISO 9001:2000, Quality management systems. Requirements<br />

Other Publications<br />

HSE Leaflet INDG218 – Guide to Risk Assessment<br />

HSE Leaflet INDG163 – Five Steps to Risk Assessment.<br />

HSE Leaflet INDG 73 – Working alone in safety<br />

HSE publication L73 - A guide to the Reporting <strong>of</strong> Injuries, Diseases <strong>and</strong> Dangerous<br />

Occurrences Regulations 1995, HSE Books.<br />

HSE publication HS(G) 107 - Maintaining portable <strong>and</strong> transportable electrical<br />

equipment<br />

Crane Stability on Site, 2003. CIRIA C703. Construction Industry Research <strong>and</strong><br />

Information Association.<br />

<strong>Cranes</strong> <strong>and</strong> planes - A guide to procedures for operation <strong>of</strong> cranes in the vicinity <strong>of</strong><br />

aerodromes. Airport Operators Association (AOA).<br />

A voluntary code <strong>of</strong> practice for the safe use <strong>of</strong> cranes in <strong>and</strong> around airports. Offhighway<br />

Plant <strong>and</strong> Equipment Research Centre.<br />

Code <strong>of</strong> practice for the safe use <strong>of</strong> lifting equipment. Lifting Equipment Engineers’<br />

Association.<br />

The <strong>Inspection</strong> <strong>of</strong> Steel Wire Ropes. CASAR Drahtseilwerk Saar GmbH.<br />

(www.casar.de)<br />

Useful Websites<br />

British Institute <strong>of</strong> Non-destructive Testing www.bindt.org<br />

Construction Plant-hire Association www.cpa.uk.net<br />

Construction Skills www.constructionskills.net<br />

Health <strong>and</strong> Safety Executive www.hse.gov.uk<br />

Safety Assessment Federation www.safed.co.uk<br />

107


Strategic Forum for Construction www.strategicforum.org.uk<br />

UK Contractors Group www.ukcg.org.uk<br />

United Kingdom Accreditation Service<br />

(UKAS)<br />

108<br />

www.ukas.com


Index (to be fully revised)<br />

109


Working Group Membership<br />

Role Name Employer Representing<br />

Health <strong>and</strong><br />

Chairman I Simpson HSE Principal Specialist Inspector Safety<br />

Executive<br />

Member M Banasik Allianz Cornhill Insurance<br />

Member N Berry Neil Berry <strong>Cranes</strong><br />

Member R Cameron Sir Robert McAlpine<br />

Member S Cooke Ainscough Crane Hire Limited<br />

Member P Harvey Terex-Demag<br />

Member E Hudson Liebherr (Great Britain) Limited<br />

Member S Leinster Marsh Plant<br />

Member J Miller Manitowoc <strong>Cranes</strong><br />

Member A Newell National Construction College<br />

Member N Purves Terex-Demag<br />

Secretary &<br />

Editor<br />

T P Watson Construction Plant-hire Association<br />

110<br />

Safety<br />

Assessment<br />

Federation<br />

CPA Crane<br />

Interest Group<br />

UK Contractors<br />

Group<br />

CPA Crane<br />

Interest Group<br />

CPA Crane<br />

Interest Group<br />

CPA Crane<br />

Interest Group<br />

CPA Crane<br />

Interest Group<br />

CPA Crane<br />

Interest Group<br />

Construction<br />

Skills<br />

CPA Crane<br />

Interest Group<br />

CPA Crane<br />

Interest Group

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